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Control room design provides operation environment with maximum work efficiency
Control Room Design
<IA-PESC-08-093>Copyright © Yokogawa Electric Corporation<April 2008>
Yokogawa Electric Corporation
Agenda
Introduction
– What is Control Room Design?
– Typical benefits
Best practices
Consulting service
– Service definition
<IA-PESC-08-093>Copyright © Yokogawa Electric Corporation<April 2008>
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– Service definition
– Features
– Workflow
– Schedule
Introduction
<IA-PESC-08-093>Copyright © Yokogawa Electric Corporation<April 2008>
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Principles of Control Room Design
Human-centered design approach– Designing suitable working environment for human safety, health,
and happiness in consideration of technical and economical efficiency.
Well-balanced integration in each design process– Human
– Facility & Equipment (Hardware & Software)
<IA-PESC-08-093>Copyright © Yokogawa Electric Corporation<April 2008>
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– Facility & Equipment (Hardware & Software)
– Working environment
– Automation systems (Operation, Monitoring, Management)
– Business policy, Business strategy
Typical Steps toward Control Room Construction
�Typical steps toward control room construction
<IA-PESC-08-093>Copyright © Yokogawa Electric Corporation<April 2008>
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Layout planning
Large screen position
Console design
Constructed control room
Typical Benefits
Safety and productivity improvement
– Reduce work stresses and related human errors
– Increase operators’ work performance
– Motivate operators to do more creative work
Compliance with specified standards and regulations
e.g.
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e.g.
– ISO 11064 Ergonomic Design of Control Centers
– Shell Human Factors Engineering - HMI & Control Room Design
Symbolization of client’s company policy
– Stance on care for employees
– Production strategy (cost center or profit center)
– Symbolic presentation to visitors
Best Practices
<IA-PESC-08-093>Copyright © Yokogawa Electric Corporation<April 2008>
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Layout based on Business Workflow
Field staff room
Gas detector
Utilitymonitoring board
Training simulatorroom
Smoking roomRefresh room
Intelligentcommunication room
Daily maintenancemanagement room
Shift ManagerRoom
Utility
Polymers
Aromatics
To polymer plant
To aromatics plant
<IA-PESC-08-093>Copyright © Yokogawa Electric Corporation<April 2008>
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Side room
Instrumentationroom
Supply room
Planning Room
Shift managerRoom
Butadiene
Ethylene
Shift manager
Utility
ButadieneAromatics
Ethylene
Planning AccountingReporting
Maintenance
Operation
To ethylene plant
Accounting &Reporting Staff
MaintenanceStaff
Workflow-basedLocation
Overhead View
Chemical laboratory
Island A
Island D
Island B
Island C
<IA-PESC-08-093>Copyright © Yokogawa Electric Corporation<April 2008>
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Locker room
CanteenRest room
Visitors room
Stairs
Layout in Consideration for Visitors
<IA-PESC-08-093>Copyright © Yokogawa Electric Corporation<April 2008>
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Dimensional Drawing
Traffic LineTraining Room
StaffRoom
StaffRoom
Canteen
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RoomRoom
Console Layout based on Ergonomics & Maintainability
The type of console grouping is referred from ISO 11064 Part3 in which Yokogawa contributed.
<IA-PESC-08-093>Copyright © Yokogawa Electric Corporation<April 2008>
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Console layout in consideration forhot cut over (DCS migration under plant operation)
Color Coordination
• Sober atmosphere• Sense of stability
• Brain activation• Energetic atmosphere
Point of color coordination
– To provide comfortable work environment
– To reduce the tiredness of eyes and bodies
– To increase work efficiency
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Warm Color Coordination Cool Color Coordination
Large Screen Setting & Glare Study (not in this phase)
Shift superintendent Board operator Temporary access
View Point 1 View Point 2
Large screen
Study for setting angle of large screen
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Study for setting angle of large screen
View Point 1 View Point 2
Study for glare / reflection
Lighting and Ergonomic Design (not in this phase)
Limit of the visual field
Limit of the colored visual field
Range of neck movement
Range of eye motion
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Lighting design (including illumination distribution)
Range of arm motion
Range of eye motion
Ergonomic design for console
Oil Refinery
Shin-nihon Oil / Osaka Refining Center
1996
Control room (1F)
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Visitors room (2F)
Visitors room (2F)
Gas Supply
Osaka Gas Co., LTD. / Senboku ⅠⅠⅠⅠ Plant
2004
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Front panel; Large screen (70 inch x2), Electric Graphic Panel, Disaster prevention Graphic Panel, Emergency SW, ITV ( 21 inchCRTx6),Annunciator, Digital Indicator
Water Treatment
Water Works Bureau of Hurue Water Purification Plant
2004
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Front panel; Large screen (70 inch x3), Digital clock
Features;1. Subsystems are located both adjacent sides of operator consoles for easy access.2. Visitor room is located next to the control room.
Gas Supply
Toho Gas Co., LTD. / Midorihama Plant
2001
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Front panel; Large screen (50 inch Multi x6), Emergency SWITV ( 29 inch CRTx2), Annunciator, Digital Indicator
Features;1. Circular arc watch panel is installed.2. Operation work is monitored by two foreman who are sitting
right behind.
Consulting Service
<IA-PESC-08-093>Copyright © Yokogawa Electric Corporation<April 2008>
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Service Definition
Control Room Design Service– Service product which Yokogawa provides the conceptual design of new
control room to newly build a comfortable, safe and functional control room.– The conceptual design includes:
• Design concept (document)• Room layout (figure)• Grounds of layout (document)
– One Control Room Design Service is applied to one control room.
Service Contents– Software & Hardware
<IA-PESC-08-093>Copyright © Yokogawa Electric Corporation<April 2008>
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– Software & Hardware• Not included
– Engineering• Development of a conceptual control room design• Preparation of a service report
– Consulting• Facilitation of team meetings• Provision of experiences
– Deliverables• Service report (conceptual control room design)
Features
Yokogawa’s 30+ years of experience as an outstanding control room designer in diverse range of industries– More than 500 projects experience of control room design
Deep understanding of production plant– Company organization, business– Business workflow, command structure in case of emergency– Engineering (e.g. chemical, control, electric, mechanical)
Centenary experiences as a control system supplier
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Centenary experiences as a control system supplier– Configuration, dimension, weight– Recommended environment (e.g. temperature, barometric pressure,
humidity, dust control)– Network– Power supply, Earth, CVCF– Functional enhancement and migration
Capable of ergonomic design– Console design– Screen setting and glare prevention– Lighting, air conditioning
History of CCR Design Work
1975 Sales release of world’s first DCS “CENTUM”1978 Launch of CCR environmental design service– Water supply: Sapporo, Kimitsu, Hanshin, Kanazawa, Ikeda, Takatsuki– Gas supply: Sendai, Tokyo, Toho, Osaka, Hiroshima, Seibu– Chemical: Mitsubishi chemical, Sumitomo chemical, Shin-etsu chemical– Oil downstream: Tomakomai east oil stock, Fukui oil stock, Koa oil, Japan energy– Electric power: Hokkaido, Tokyo, Chugoku, Shikoku, Kyushu– Iron & Steel: Shin-nihon steel, Kawasaki steel, Kobelco, NKK, JFE steel– Waste treatment: Adachi, Kurito– Food: Nissin oil manufacture, Suntory, Nikka whiskey– Sewage farm: Saibara
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– Sewage farm: Saibara– Paper & Pulp: Ouji paper & pulp, Marusumi paper & pulp– Oversea: Caltex, Tuas, Mobil– Others: Japanese red cross, Yokogawa response center
1999 Launch of CCR interior finish work (Production) service2000 Sales release of original desk “FDDS”2003 Sales release of information interface board “ECCR”
Launch of CCR design consulting service2005 Sales release of original desk “Pride”
More than 500 projects experiences
Workflow
Define– Define target for control room design
Measure– Use questionnaire to acquire customer information
Analyze– Analyze clients' needs based on acquired information
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– Analyze clients' needs based on acquired information
Improve– Prepare conceptual design
Control– Issue and introduce conceptual design
– Advise on next activities
Define
Define target for control room design
e.g.
– Comfort
– Safety
– Functionality
– Innovation
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– Innovation
Measure
Use questionnaire to acquire customer information
– Plant
– Building
– System
– Project
– Operation
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Survey existing control room (where possible)
– Control room layout
– Traffic flow
• Operator console layout
• Human machine interface
• Panel
• Fixtures and furniture
Example of questionnaire
Category Considerations Purpose Examples
1. Room Dimension
Location Accessibility to a target plant
Aspect, Direction Lighting and anti-glare
Flooring Networking and lighting Type (pit, free access), height of ceiling
Window Lighting and anti-glare w/ or w/o, location, size
Door Accessibility to a target plant Location, Number, Size (for system installation)
Building codes and standards Compliance with standards ISO 11064 Ergonomic Design of Control Centers
Religious custom/National backgrounds Comfort Prayer space, color preference
2. Systems Configuration and access frequency Optimal system/desk location DCS (Console, Controller), SIS, PC, Workstation, Panel
Network structure and necessary performance Optimal system/desk location Proprietary bus, Ethernet
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3. Operation Ladder Optimal system/desk location Foreman, board, field, staff
Official responsibility Optimal system/desk location Supervision, operation, field works
Operational state Optimal system/desk location Normal, emergency, transition, start-up, shut-down
Operational shift, rotation Optimal system/desk location 3 shift, 4 rotation
Business workflow by operational state Optimal system/desk location
Number of people per shift Optimal system/desk location Foreman 1, board 6, field 4
Number of people per operational state Optimal system/desk location
Meetings Meeting room design Purpose, frequency, duration, head-count
4. Project Purpose of construction/renewal Logical planning Control room consolidation, System migration
Project organization chart Efficient hearing
5. Others Timing of system enhancement/migration Space-consuming
Visitors Construction of visitor room
Analyze
Analyze clients' needs based on acquired information
<IA-PESC-08-093>Copyright © Yokogawa Electric Corporation<April 2008>
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Improve
Prepare a conceptual design that includes as follows:
– Design concept (document)
– Room layout (figure)
– Grounds of layout (document)
<IA-PESC-08-093>Copyright © Yokogawa Electric Corporation<April 2008>
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Room layout
Chemical laboratory
Island A
Island D
Island B
Island C
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Locker room
CanteenRest room
Visitors room
Stairs
Control
Issue and introduce a conceptual design
Advise on next activities
e.g.
– Basic design
– Detailed design
<IA-PESC-08-093>Copyright © Yokogawa Electric Corporation<April 2008>
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– Detailed design
– Manufacturing
– Construction
Next Activities
Schedule
Activity
Target setting
Client
✔
Yokogawa
Step
D
Site/Office
S
Comprehend the provideinformation
Survey existing control room ✔
✔
✔
M
A
O
S
1st month 2nd month
Prepare the answers toquestionnaire
✔M S
<IA-PESC-08-093>Copyright © Yokogawa Electric Corporation<April 2008>
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•Yokogawa covers this service in a total period of two months maximum.•DMAIC cycle is executed once in one Control Room Design Service.
Survey existing control room ✔✔A S
Develop a conceptual design
Customer support by telephoneand/or e-mail
Issue and introduce a conceptualdesign
✔
✔
✔
I
I
C
O
O
S
Analyze requirements by interview ✔✔A S
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Thank you very much for your attention