ICM1100 Control Room Design

1100 Control Room Design

AbstractThis section describes the practices used for the design of control rooms for process plants and for onshore producing facilities. It explains the location of the control room in relationship to the facility processes and discusses pertinent architectural criteria. Design guidelines are prescribed for types of control panels and auxiliary control equipment.

Contents Page

1110 Introduction 1100-3

1111 Definitions of Control Room Types

1120 Background 1100-4

1121 Engineering and Coordination

1130 Design Parameters 1100-4

1131 Environmental Parameters

1132 Physical Parameters

1133 Utilities

1140 Prerequisites and Procedures 1100-5

1141 Design Documentation

1142 Local Control Room Prerequisite Data

1143 Central Control Room Prerequisite Data

1144 Design Procedure Sequence

1150 System Requirements for Control Room Design 1100-6

1151 Air-Conditioning and Filtering

1152 Pressurization and Purging Systems

1153 Utilities

1154 Gas Detection and Fire Detection and Extinguishing Systems

1155 Plant Communications Systems

1160 Design Concepts 1100-8

Chevron Corporation 1100-1 July 1999

1100 Control Room Design Instrumentation and Control Manual

1161 General Considerations

1162 Building Requirements

1163 Control Room Environment

1164 Pneumatic Tubing and Cable Design

1165 Layout Considerations for Control Panels

1166 Layout Considerations for Control Rooms Housing Distributed Control Systems

1167 Layout Considerations for Auxiliary Equipment

1168 Local Control Room Design Concepts

1169 Central Control Room Design Concepts

1170 Checklist and Final Documentation 1100-24

1171 Checklist for Control Room Design

1172 Final Documentation

1180 Sample Control Room Design Criteria 1100-30

1190 References 1100-34

1191 Model Specifications

1192 Other References

July 1999 1100-2 Chevron Corporation

Instrumentation and Control Manual 1100 Control Room Design

1110 IntroductionThis section provides guidelines for the construction of new control rooms and for major modifications to existing control rooms for processing plants and onshore producing facilities.

This section has limited applicability for the design of control rooms on offshore platforms, because they have requirements unique to the application.

Local conditions, traditional methods of control room construction, and the specific requirements of the project and ultimate user will determine the extent to which the designer should follow this guideline. The designer is urged to utilize local exper-tise to supplement guideline recommendations.

1111 Definitions of Control Room TypesFor the purposes of this section, a control room is defined as an enclosed modular building or permanent structure at a major facility that can contain control panels, consoles, and associated control equipment. It can include a field termination (rack) room, computer equipment room, offices, utility and mechanical equipment rooms, and other facilities necessary for the efficient and safe operation of the facility. The two types of control rooms discussed in this section are local control rooms and central control rooms.

Local Control RoomThe local control room is used in specialized areas such as turbine-driven generator systems, laboratories, drilling controls, and furnaces or heater systems. The local control room may be manned or unmanned.

The manned local control room may be occupied 24 hours per day, with occasional absences for field checking of process equipment and conditions. All or only selected critical parameters from the information gathered or generated in the local control room may be transmitted to a central control room depending on ultimate design decisions. Typically, the manned local control room is adjacent to the process it maintains.

The unmanned control room contains control equipment that allows local moni-toring and limited control of a unit, individual process, or small plant. Personnel will visit the unmanned local control room occasionally to perform maintenance checks or to obtain process information not available in the central control room.

Central Control RoomThe central control room monitors and controls process operations, fire and gas protection, and communications. The control room may incorporate one or more offices depending on project requirements. In addition, the central control room can gather process data from local control rooms distributed throughout a facility or from remotely located controls, such as analyzer sheds or remote terminal units, that are commonly found in process plants and on pipeline facilities.



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1120 Background

1121 Engineering and CoordinationThe engineering disciplines required for the design of a control room include the following:

1. Instrument engineering, to design control systems, lay out the man-machine interface, schedule equipment components into enclosures, determine power requirements, and provide overall coordination for the other disciplines

2. Electrical engineering to provide power distribution, lighting, and cable routing

3. Architectural and structural engineering to provide room or building design in accordance with personnel requirements and blast resistant design if appro-priate

4. Safety engineering to provide detection and alarm systems and to assist in the selection of nontoxic and fireproof materials

5. Mechanical engineering, to provide heating, ventilation and air-conditioning (HVAC) infrastructure, piping design for fluid utilities, and assistance with fire detection and extinguishing systems

1130 Design ParametersThe following parameters should be considered in order to implement the control room design procedure.

1131 Environmental Parameters• Climatic conditions at the site—minimum and maximum temperatures and

tive humidity, maximum wind velocity, and prevailing wind direction

• Ambient air quality—location of the control room relative to known or potential sources of airborne pollutants

• Unusual phenomena—dust or sand storms, flash flooding, salt spray, etc.

• Seismic zone classification

1132 Physical Parameters• Weight and size restrictions for major equipment or modules to be installed

the site, and access by transport and cranes

• Soil loading conditions (Major control house expansion might require pile setting of building and underground duct banks.)



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• Proximity of grade to water table, if underground cable vaults are planned

• Drainage, and susceptibility of grade areas to flash flooding

1133 Utilities• Electrical power availability• Potable water availability• Instrument air supply• Drainage and sewer line availability

1140 Prerequisites and Procedures

1141 Design DocumentationPreliminary control room design is developed from the following documentation

1. Area electrical classification plan

2. Plant or platform preliminary layout

3. Control system conceptual layout

1142 Local Control Room Prerequisite Data1. Specialized functions, e.g., turbine generator control room, motor control

center, orlist1ation

2. Manned or unmanned

3. Type of communications available

1143 Central Control Room Prerequisite Data1. Personnel requirements—operating, technical, and administrative

– Changing room– Lavatories– Lunchroom– Maintenance area

2. Control, shutdown, and environmental monitoring systems requirements

– Physical size, layout, and location– Power consumption– Interface requirements



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1144 Design Procedure Sequence1. Review data obtained in Sections 1131, 1132, 1133.

2. Obtain prerequisite data as described in Sections 1141, 1142, and 1143 as applicable.

3. Review Section 1150 to determine systems required in the control room design.

4. Complete the system design after reviewing the design concepts covered in Section 1160.

1150 System Requirements for Control Room DesignThe systems that may be included in the design of a control room are air-condi-tioning and filtering, pressurization and purging, fire detection and protection, gas detection, and communications (if required). These systems are discussed in the following sections.

1151 Air-Conditioning and FilteringAn HVAC system is required in any control room containing personnel or tempera-ture-sensitive electronic equipment. The HVAC system may also serve as the pres-surization system. The HVAC system design should follow the recommendations in Specification ICM-MS-3651, Section 5.0.

Window-mounted air-conditioners may be used in place of central HVAC systems in tropical and subtropical climates where heating is not required for personnel comfort, provided that they provide equivalent air filtering for personnel protection, are rated for the electrical area classification of the control room, and draw fresh air from an area that does not increase the hazard to personnel or equipment.

1152 Pressurization and Purging SystemsAlthough the Company does build purged and pressurized control rooms and build-ings, this is done primarily to prevent air contamination. Such rooms and buildings are normally located in unclassified areas only, an exception being offshore plat-forms. Offshore control rooms located in hazardous areas require positive pressure inside to keep the hazardous vapors or gases from infiltrating the control room.

The design rules and code requirements for purging and area classification are extensive. The design engineer should refer to the following documents:

• National Fire Protection Association (NFPA) Standard No. 496, “Purged anPressurized Enclosures for Electrical Equipment”

• API RP 500 Classification of Locations for Electrical Installations at Petro-leum Facilities Classified as Class I, Division 1 and Division 2.

• API RP 505 Classification of Locations for Electrical Installations at Petro-leum Facilities Classified as Class I, Zone 0, Zone 1, and Zone 2.



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• Instrument Society of America (ISA) RP 12.1, “Electrical Instruments in Hazardous Atmospheres”

• Electrical Manual, Section 300, “Area Classification”

1153 UtilitiesThe utilities required for most control room installations include electrical powerinstrument-quality compressed air, and potable water and drain systems.

Electrical power systemsControl room electrical power requirements can include any or all of the followin

1. 12 VDC, 24 VDC, or 120 VAC, all with UPS, for instrumentation and controsystems

2. 12 VDC or 24 VDC for paging and alarm systems

3. 120 VAC for lighting and receptacles

4. 12 VDC, 24 VDC, or 120 VDC, all with UPS, for emergency lighting system

5. 12 VDC, 24 VDC, or 120 VAC, all with UPS, for fire and gas detection systems

6. 208 or 480 VAC, 3-phase, 60 Hz for HVAC systems

7. 12 VDC, 24 VDC, or 120 VAC, all with UPS, for radio systems

8. 48 VDC with UPS for microwave systems

9. 120/240 VAC for computers and peripherals

For the purpose of the above list, a DC “UPS” consists of a battery charger, a storage battery bank, and sufficient auxiliary instrumentation to monitor and contheir functions.

The electrical supply and distribution system for the control room should follow recommendations in Specification ICM-MS-3651, Section 4.0.

Water and Drainage systemA potable water supply for the control room may be required for water fountainslaboratory sinks, restrooms, and changing rooms in process plants. Piping shoudesigned in accordance with the project piping specifications and applicable national, state, and local building codes. Drains must also tie into the appropriadrainage systems—process or sanitary. Tie-ins to process drains must be gas s(Civil and Structural Manual, Section 500).

Air supplyInstrument air for the control room is used for pneumatic instrumentation and possibly for the laboratory. Piping should be designed in accordance with the pr



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piping specifications, ISA RP 60.9, “Piping Guide for Control Centers,” and ISA S7.3 “Quality Standard for Instrument Air.”

1154 Gas Detection and Fire Detection and Extinguishing SystemsGas detection and fire detection and extinguishing systems should follow the guidelines in the Fire Protection Manual and in Specification ICM-MS-3651, Section 6.0.

1155 Plant Communications Systems

In-plant communications systemThe in-plant communications system enables communications between field optors, local control rooms, and the central control room. Equipment selected for application can include sound-powered phones, local telephone system extensintercom sets, radios, or combinations of two or more types of equipment. In-plsystems can also include the ability to announce plant emergencies such as fireaccidents, and evacuation signals. System design should limit traffic to that whiof interest to a single plant area.

Interplant communications systemThe interplant communications system enables communications among two or plants within a facility. Additional equipment can include dedicated phone systefor process—or system-specific communications (e.g., dedicated to utilities useto communications between H2S producers and recovery plants) and radios for communications with agencies outside the facility.

CoordinationThe design of these systems should be coordinated with the TelecommunicatioDepartment.

1160 Design Concepts

1161 General ConsiderationsThe following criteria should be considered for control room designs.

Safety considerationsSafety considerations should include area classification, location in relation to csified areas, fire and gas protection, blast protection, and proximity to escape ro

Area classificationThe control room is preferably located in an unclassified area. This requiremenextremely critical for both personnel and electronic equipment. If a control room



must be located in a hazardous location, it should be pressurized and have an airlock or satisfy API RP 500 or RP 505.

LocationThe control room design should account for prevailing wind. Whenever possible, locate the control room upwind of the process area. This will minimize the potential for process gas accumulation in the control room area. All control room air intakes should be located upwind of the process area and in an unclassified area. It may be desirable to install combustible or toxic gas sensors in or near air intakes.

Fire and gas protectionFire protection systems are required for all control rooms. These systems include heat and smoke detection systems and fire extinguishing systems. The systems should be designed according to the Fire Protection Manual.

Combustible and toxic gas detection systems for control rooms must provide two functions: (1) alert personnel to the presence of these gases within the monitored area, and to abnormal operation of sensors and interface electronics; and (2) take corrective action upon detection of gases (e.g., shut in sources).

Gas detection systems should be designed in accordance with the Fire Protection Manual.

Gas detection systems for offshore platforms must be designed in accordance with API RP 14F and ISA RP 12.13.

Proximity to escape routesThe control room design should consider proximity of the control room to escape routes for emergency evacuation. Control rooms should have at least two exits that are as distant from each other as is practical, on the basis of good engineering judgment.

External interference considerationsThe design of the control room should address and minimize the effects of noise and vibration, electromagnetic interference (EMI), and radio frequency interference (RFI).

Ambient noise and vibration should be minimized by proper control room location, installing soundproofing, and providing equipment vibration damping.

EMI can be minimized by segregation of power and control wiring, selection of signal levels for transmission, shielding and grounding of cables, and equipment grounding. The recommendations of Section 3.0 of Specification ICM-MS-3651 should be followed. RFI can be minimized by selection of equipment enclosures, physical isolation between sources and RFI-susceptible instruments, and implemen-tation of procedures to minimize RFI generation near sensitive instruments.



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Accessibility and communicationsA control room design should include a method for communicating with the process areas. It may be desirable to include a page-party system with loudspeakers and handsets throughout these areas and the control room.

Unmanned control rooms should provide telephone or page-party communications for occasional visits by personnel. If the unmanned control room is entirely auto-mated, a supervisory control and data acquisition (SCADA) system may be required for data communications to a manned control room.

Ambient nose considerationsControl room design and equipment selection should recognize the need to limit the ambient noise level within work areas.

Data loggers and report printers are significant noise generators. Printers other than those supplying data needed by the operator at his work station should be installed in a separate room. Printers located at the operator work station can be fitted with noise reduction shrouds to lower ambient noise levels.

Air-conditioning systems (especially window-mounted units) can be an additional source of high ambient noise levels. HVAC equipment selection and layout and duct design can minimize the transmission of noise into the control room.

Cooling fans installed in electronic equipment racks are another potential noise generator. Where control room layout does not permit installing this equipment in a separate rack room, soundproofing on the inside of rack doors and routing of hot air exhaust ducts away from the operator work area can minimize ambient noise.

Kitchen facilitiesGeneral control rooms frequently include facilities for preparing and consuming operator meals. Cooking equipment, especially range tops and conventional ovens, generates aerosol greases which can damage electronic circuit boards. Kitchen facil-ities design should include a vent hood over cooking equipment which discharges outside the control room structure and HVAC return air ducts from the kitchen area should be segregated from those in the remainder of the control room.

Changing rooms for central control rooms in process plantsThese locker and shower facilities should be designed so that personnel are provided with a “dirty” changing area having direct access to the showers and srated from the clean dressing areas with a walk-through passageway that can bused when arriving personnel change into workclothes.

1162 Building RequirementsArchitectural features also influence control room design. See Section 400 of thCivil and Structural Manual for guidelines on the civil and structural aspects of small buildings, blast resistant design, and hurricane resistance.



General requirementsThe control room may be single- or multistory. Typical arrangements for single- and two-story control rooms are shown in Figure 1100-1. A local control room should be designed around the equipment to be located in the room. This applies to the physical layout of the control room as well as to the architectural design of the room.

Windows and doorsControl room windows are usually located to enable viewing as much of the process area as possible. Where windows are provided, several design requirements exist:

1. If a window is located in a wall required to be fire-resistant, it should be of fixed-frame construction, and glazed with heat-resistant, shatterproof glass.

2. If the control room is pressurized, window frames and windows should be sealed such that internal pressure can be maintained.

3. If high ambient noise surrounds the control room, double-glazed windows might be required to reduce noise. (This technique typically attenuates noise by 10 to 15 decibels.)

Refer to Specification ICM-MS-3651 for additional guidelines.

In a local unmanned control room, windows should be kept to a minimum. Unless the design demands it, windowless rooms are preferred. In manned local control rooms, windows may be needed to view the process being controlled. Sometimes windows are not needed for viewing (for example, in a manned control room for internally mounted switchgear) but should be provided to meet the goals of human engineering.

At least two doors, preferably at opposite ends of the control room, must be provided to allow multiple escape routes for personnel. Doors should open in the direction of the escape path, and be fitted with panic bar hardware.

At least one of these doors should be sized to allow for the movement of major equipment into and out of the control room. The maximum size door without mechanical helpers is a double door, 6 feet wide by 7 feet high. If equipment sizing dictates a larger access opening, install a removable transom or a removable wall panel.

Doors should be metal with integral frames, and might require soundproofing to attenuate ambient noise.

Unless impossible, doors should not be located in a fire-resistant wall.

LightingThe designer should incorporate two lighting systems in the control room design: a primary system for normal operation and an emergency system to be activated on failure of the primary system.



Fig. 1100-1 Control Rooms (Typical)

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The lighting systems should be designed in accordance with the Electrical Manual, Section 1700, “Lighting.” Figures 1100-2 and 1100-3 show typical layouts of normal and emergency lighting.

Emergency lighting is recommended in all manned control houses, to allow ordshutdown of the facility in the event of a power failure, and permit safe exit fromthe control room.

Fluorescent lighting fixtures are recommended for most applications to achievenormal lighting levels required. This type of fixture reduces glare and power consumption. Ceiling, wall, and floor reflectance can also be utilized to obtain aglare-free lighting environment.

Ceiling designThe issues of fire resistance and the functionality of ceiling spaces must be addressed prior to design of a control room ceiling.

The need for fire-resistant construction is determined by what is above the conroom ceiling.

The desirability of a suspended ceiling is determined by whether the space abowill be used, or might be used at a future date, for the routing of HVAC ducting,utilities, or control system cabling.

A suspended ceiling, using T-rail construction and removable acoustic panels, irecommended for control rooms housing primarily electronic instrumentation, because this configuration allows for substantial future changes to the instrumetion and its connecting cabling.

A flat suspended ceiling with acoustical tiles permanently attached to the false-wcan provide space for routing ducting, utilities, and cabling, but lacks flexibility finstalling instrumentation cabling additions.

Both configurations of suspended ceiling allow for installation of flush-mountedfluorescent lighting fixtures and the easy reconfiguration of lighting fixture layouas required by realignment of equipment and furniture within the control room.

A solid flat ceiling offers none of the functionality of either configuration of suspended ceiling, but has the lowest installed cost. A flocked finish should be considered as a cost-effective method of noise and glare reduction.

Ceiling height above the floor should be determined by the requirements of theequipment planned for the control room, and should be a minimum of 9 feet; usa greater height adds to the esthetics of larger control rooms.

Floor designThe floor design of the control room is dependent on the following criteria: the tof equipment to be mounted in the room (electronic or pneumatic), fire protectiosystems, method and location of wiring, and coordination with remaining buildindesign considerations for lighting, wiring, and ventilation.



Fig. 1100-2 Reflected Ceiling Plan



Fig. 1100-3 Control Building: Lighting and Small Power Plan



A raised floor in conjunction with a suspended ceiling should be considered for electronic equipment. Both floor and ceiling then provide space for cable intercon-nection of equipment and act as plenums for ventilation. A raised floor 12 inches above the primary floor should provide sufficient clearance in most applications. The designer should ensure that the raised floor is capable of supporting the weight of the installed equipment as well as the expected traffic load without noticeable flexure. Also, the floor height is dependent upon the seismic zone in which the facility is located. If no electronic equipment is located in the control room, the designer may consider using a solid floor to reduce costs.

For either construction, both fire protection requirements and the color and texture coordination of the room for eliminating glare and optimizing lighting levels must be satisfied.

For additional guidelines, see Specification ICM-MS-3651, Installation Require-ments for Digital Instrumentation and Process Computers.

1163 Control Room EnvironmentThe environment of the control room should be comfortable for human occupancy and should protect the equipment located there. If the control room is located in a hazardous area, it should be purged or designed in accordance with API RP 500 or RP 505. Through-traffic paths should be arranged so that personnel track in the minimum amount of dirt as they walk through the room. Some Company locations issue disposable plastic overshoes to personnel as they enter the control room.

1164 Pneumatic Tubing and Cable DesignDesign considerations for cable or pneumatic line entry into a control room are dependent on whether the room is pressurized and whether entry is through walls requiring fire-resistant rating or required to be vapor tight.

If the control room is pressurized, the entries should be sealed sufficiently to main-tain the room internal pressure.

If the control room is not pressurized, and if the walls are not required to be fire-resistant or vapor tight, the entries should be weather-tight.

In either case, the entries and adjacent areas for cable, conduit, or tubing routing should provide a 50% (minimum) allowance for future expansion.

For a pressurized control room cable entry, a multicable transit as shown in Figure 1100-4 or equivalent entryway should be used. Individual pneumatic tubing entries to pressurized control rooms should be routed via bulkhead fittings as shown in Figure 1100-5.

The interior layout of cables and pneumatic tubing is a function of the control room layout and type of entry into the cabinets or consoles. If the equipment is bottom entry, a raised floor should be considered. Conversely, if the equipment is top entry, a false ceiling should be considered. When a combination of top and bottom entry is used, the designer should consider either a raised floor and lowered ceiling or one of



Fig. 1100-4 Multicable Transit (Courtesy of Nelson Fire Stop Products)

Multicable transit is based on a simple but effective design. It consists of a rectangular metal frame suitable for floor or wall installation, which is avail-able in single or multiple units. Each frame contains an arrangement of Tecron elastomer modules grooved to fit snugly around cables, pipes, or conduit passing through the frame. The Tecron modules expand when exposed to heat, providing a contin-uous seal even if cable jackets disin-tegrate. The entire assembly within each frame is locked in position to prevent dislodgement and the spread of fire and the products of combustion.

TRANSIT FRAMEThe transit frame is the housing into which the other components are fitted.

MCT LUBRICANT (TALLOW)Used when packing. Allows the insert modules to slide easily over each other.

RTV-106 SEALERFor armored cable. Sealer should be applied in the grooves to seal the space between the armor and the cable sheath in navy cables, and the groove in the interlock of industrial cables.

COMPRESSION BOLTWhen tightened, the bolt applies pres-sure to the compression plate sealing the grooved insert modules around the cables.

END PACKING—STANDARDEnd packing assembly is bolted into place to provide a fire and watertight seal above the compression plate. The standard end packing assembly is used when both sides of the transit frame are accessible.

END PACKING—SPECIALThe special end packing assembly serves the same purpose as the stan-dard and is used when the transit frame is accessible from only one side.

COMPRESSION PLATEThe compression plate acts as a pres-sure plate above the internal assembly.

STAY PLATESStay plates are inserted between every completed row to help distribute compression forces within the frame and to keep modules from dislodging under high pressure conditions.

GROOVED INSERT MODULESGrooved insert modules are available in seven module sizes to accommodate a range of cable/pipe from 5/32 in. to 3-3/4 in. O.D. They fit snugly around the cable or pipe to form an air-tight, water-tight seal when compression is applied in final assembly step.

SPARE INSERT MODULESSolid modules are used to fill voids or allow for future addition of cables. They are available in 3 module sizes.

FILL-IN INSERT STRIPSUsed to fill space gaps. Available in two thicknesses; 5 and 10 mm. Strips are 120 mm long and are split to allow cutting at any desired length.



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the two with appropriate routing to the equipment with opposite entry. Typical routing techniques are shown in Figure 1100-6. Instrument, alarm, thermocouple, and control wiring should be separated.

1165 Layout Considerations for Control PanelsTwo factors affect control room arrangement: space required and use of conven-tional panels or shared-display (CRT) systems. Typical arrangements for conven-tional and shared-display systems and associated equipment are shown in Figures 1100-7, 1100-8, and 1100-9.

General considerations for operator work areasThe design of the control room layout should ensure that the operator work area is separated from the flow of traffic through the control room and from nonopera-tional work areas. Appropriate communications to the operator work station should be provided.

ClearancesThe designer should maintain minimum clearances around control equipment to provide work space for operations and maintenance and to facilitate ventilation. The following minimum clearances should be included in the control room design:

• Operations and maintenance access: 4 feet, or as required by local electriccode, whichever is greater

• Overhead clearance for panels: 1 foot

Selection of control equipment requiring front and rear access should consider additional space requirements for access and the size limitations of the control room. Conventional control panel design is frequently a mimic representation oprocess in the area above instrumentation; this frequently increases panel size

Fig. 1100-5 Typical Bulkhead Connections



Control panels should be built in accordance with Specification EG-1348, Shop-Fabricated Control Panels.

Color considerationsA panel background color that compromises between maximum contrast and no contrast should be specified. The compromise should lean slightly toward less contrast.

1166 Layout Considerations for Control Rooms Housing Distributed Control Systems

Distributed control systems (DCS) control rooms typically contain operating consoles, one or more video displays and printers, and magnetic data storage devices. The circuit board rack comprising the microprocessor-based controllers may be located in the console under the CRTs, in a separate cabinet in the control room, or in the “rack” room. A typical arrangement found in Company process plants is shown in Figures 1100-8 and 1100-9.

Fig. 1100-6 Cabling and Tubing Rooms, Process Plant Central Control Room (Example)



Fig. 1100-7 Shared Display (CRT) and Conventional Panel Control Systems



Fig. 1100-8 Offshore Control Building: Electrical Plan

1. NAV AID BATTERY RACK

2. 125 VDC BATTERY RACK


4. 24 VDC BATTERY (CONTROL) RACK

5. 24 VDC BATTERY (GENERATOR) RACK


7. 24 VDC DISTRIBUTION BOARD

8. 24 VDC U.V. CONTACTOR

9. NAV AID BATTERY CHARGER

10. 24 VDC CONTACTOR FOR SOLAR GENER-ATOR

11. 24 VDC BATTERY CHARGER




15. 125 VDC EMERGENCY LUBE PUMP STARTER

16. 125 VDC DISTRIBUTION BOARD

17. 24 VDC CONTACTOR (SOLAR LUBE)



20. 125 VDC U.V. CONTACTOR

21. 125 VDC 30A MAIN 3 2

22. 125 VDC MAIN BREAKER PANEL

23. 480 VAC POWER DISTRIBUTION PANEL

24. 208 VAC LIGHTING PANEL

25. A/C DISTRIBUTION PANEL

26. A/C DISTRIBUTION PANEL

27. 480V SWITCHGEAR

28. 480V MCC

29. 125 VDC HALON LATCHING RELAY

30. 4160 SWITCHGEAR

31. "C" TRAIN COMPRESSOR CONTROL PANEL

32. CENTRAL CONTROL PANEL

33. "D" TRAIN (FUTURE)

34. INSTRUMENT AIR PANEL

35. 3 INVERTERS (STACKED)

36. GENERATOR PANEL #1

37. GENERATOR PANEL #2

38. PLC LOGIC PANEL

39. FIRE DETECTION PANEL

40. GAS DETECTION PANEL



43. TRANSFORMER 4160/480 VOLT

44. WATER CHILLER UNIT #1

45. WATER CHILLER UNIT #2

46. WATER FOUNTAIN

47. WALL MTD HAND SET/SPEAKER AMPLI-FIER

48. LINE BALANCE ASSEMBLY

49. MULTI-TONE GENERATOR

50. CONE SPEAKER

51. DESK TOP HANDSETS/SPEAKERAMPLIFIER

52. AMPLIFIER

53. P/C TERMINAL

54. 45 KVA TRANSFORMER

55. 24 VDC 70 AMP MAIN BREAKER



58. 24 VDC STARTER (SOLAR LUBE)

59. U.V. DETECTION PANEL


1100 Control Room Design

Instrumentation and Control M

anual

July 19991100-22

Chevron Corporation

Fig. 1100-9 Typical Process Plant Central Control Room Building Arrangement with Shared Display Control System


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ClearancesThe designer should maintain the same minimum clearances for operations and maintenance access to non-console equipment as described in Section 1165. Addi-tional clearance for operator access to consoles is required to allow passage behind an operator seated at a work station. Care must be taken to account for the width of integral work surfaces mounted to consoles. Operating personnel must be able to easily access and operate the consoles while seated.

Lighting and contrast considerationsNormal lighting considerations (see Section 1162) are usually acceptable. However, a major difficulty is the glare problem on video displays. Glare reduction tech-niques include use of spotlighting, rearrangement of lighting fixtures, installation of glare shields on video monitors, and use of light diffusers on new or existing light fixtures.

1167 Layout Considerations for Auxiliary EquipmentAs shown in Figures 1100-8 and 1100-9, auxiliary equipment can include field wiring termination cabinets, programmable logic controllers, specialized equipment controllers (e.g., for compressors), printers, computer interface equipment, and data storage units. Only printers used by the operator for critical messages should be located in close proximity to the operator work station. All other printers should be located away from the operator work station, ideally in a separate room, to mini-mize noise level.

The designer should specify the color of the auxiliary equipment to accomplish a “soft” contrast with the room color.

Routing of cables and tubing to or between auxiliary equipment should be planto avoid interference or difficulty in installing and maintaining the particular typeequipment.

Batteries for supplying standby power to control systems, emergency lighting (except for self-contained emergency lighting packs or exit signs), and communtions systems should be housed in a separate room provided with adequate vetion to prevent the accumulation of hydrogen gas generated by battery charging

1168 Local Control Room Design ConceptsLocal control rooms may be manned or unmanned, depending on the applicatioUsually, the local control room will be equipped to provide local monitoring and control of large equipment (drilling rig, motor control center, etc.) or a segment the overall process.

Technically, little or no attention is required for personnel comfort in the design an unmanned local control room. However, for a number of reasons (e.g., protetion of equipment, declassification of the area to permit the use of less costly inmentation, and comfort of operating and maintenance personnel), some unmanlocal control rooms should be designed so they can be manned.



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The designer should consider a means to transmit the monitored information back to a remote control center.

1169 Central Control Room Design ConceptsThe central control room is normally equipped to monitor and control process func-tions and peripheral support equipment for the facility. Office space for supervisory personnel should be provided within the control room building. Additional facilities that might be included within the control room building include:

• Office space for technical specialists

• Lavatory facilities

• Kitchen and eating facilities

• Storage closets for consumable stores used in the control room (e.g., chartrun sheets, etc.)

Highly flammable, volatile, or toxic materials should not be permitted in the conroom.

If laboratory facilities are provided within the control room building, they shouldprovided with separate outside entry doors and be furnished with an independeHVAC system or with window-mounted air-conditioners, as discussed previouslthis guideline.

1170 Checklist and Final Documentation

1171 Checklist for Control Room DesignThe checklist shown in Figure 1100-10 lists the data required for sizing, constructing, and providing accessories and utilities for a control room. Additiondata which amplifies on these requirements may be appended to this checklist.

1172 Final DocumentationThe following documentation should be created:

1. Control room location plan

2. Control room layout drawings (showing floor plans and equipment elevatio

3. Layout drawings for pneumatic tubing and electrical power and signal cable

4. Area lighting analysis

5. Lighting layout drawing

6. Specifications for the following:

– Building walls



Fig. 1100-10 Checklist for Control Room Design (1 of 5)

A. CONTROL ROOM TYPE (Check one.)

1. Local Unmanned

2. Local Manned

3. Central

_______

_______

_______

B. CONTROL HARDWARE (Check and specify all that apply.)

TypeSize

(L × W × H) Front Access:

Rear Side(s)Signal Entry:

Top Bottom

1. Free-Standing Control Panel _______ ________ ______ ______ ______ ______ ______

2. Console Control Panel _______ ________ ______ ______ ______ ______ ______

3. DCS Console _______ ________ ______ ______ ______ ______ ______

4. Control Racks _______ ________ ______ ______ ______ ______ ______

5. Wall-MountedControl Panel _______ ________ ______ ______ ______ ______ ______

6. Printer _______ ________ ______ ______ ______ ______ ______

7. Other (Specify):

a. ____________________

b. ____________________

c. ____________________

________

________

________

______

______

______

______

______

______

______

______

______

______

______

______

______

______

______

C. SIZE REQUIREMENTS

1. Floor Area:

a. Operator Work Area: ________ sq. ft.

b. Equipment Area: ________ sq. ft.

c. Maintenance Area: ________ sq. ft.

d. Storage Area: ________ sq. ft.

e. Office Area: ________ sq. ft.

f. Lavatory Area: ________ sq. ft.

g. Kitchen Area: ________ sq. ft.

h. Laboratory Area: ________ sq. ft.

i. Passageways: ________ sq. ft.

j. Other: ________ sq. ft. (Specify use): ______________________

2. Ceiling Height: ________ in.

3. Other Sizing Data: _______________________________________________________



D. ENVIRONMENTAL REQUIREMENTS (Check all that apply; specify required data.)

1. Cooling _______ Maximum Ambient Temp., °F___

2. Heating _______ Minimum Ambient Temp., °F___

3. Dehumidification _______ Maximum Humidity, ____ R.H. at ___°F

4. Air Purification _______ Airborne Contaminants:______________________________

5. Pressurization _______

6. Sanitary Facilities _______

7. Noise Abatement _______ Ambient Noise Level: _____ dBA

8. Other _______ (Specify)_________________________________________

E. FLOORS

1. Type: (Check one.) _________

a. Solid _________

b. Raised _________

c. Other _________ (Specify)____________________________

2. Covering: (Check all that apply.)

a. Skid-Resistant _________

b. Chem-Resistant _________

c. Other _________ (Specify)____________________________

F. WALLS

1. Construction (Check all that apply.)

a. Fire-Resistant _________

b. Insulated _________

c. Soundproofed _________

d. Other _________ (Specify)____________________________

2. Penetrations (Check all that apply; specify where appropriate.)

a. Doors:

(1) Number _________

(2) Size _________

(3) Accessories _________

b. Windows:

(1) Number _________

(2) Size _________

(3) Accessories _________




c. Entries:

(1) Removable Transoms _________ Number: _____ Size: ______________

(2) Cable Entryways _________ Number: _____ Size: ______________

Method of Sealing: _______________________________________________________

(3) Tubing Entryways _________ Number: _____ Size: ______________

(4) Other Entries _________ (Specify)______________________________

d. Other Penetrations _________ ______________________________(Specify)

3. Finish

a. Interior Surfaces (Type) _________ (Color) _______________________________

b. Exterior Surfaces (Type) _________ (Color) _______________________________

G. CEILING

1. Construction (Check all that apply.)

a. Fire Resistant _______

b. Insulated _______

c. Suspended _______ Specify type: T-rail__ Permanent______________

Plenum height: ___ in.

d. Noise resistant _______

e. Other _______ (Specify)________________________________________________

2. Finish (Type)_________________________ (Color)__________________________

3. Other Features: ___________________________________________________________________________

H. LIGHTING

(Note: If lighting requirements vary within control room, attach additional copies of this section to Checklist and reference by area or room.)

1. Type (Check one.)

a. Fluorescent, flush mount _________

b. Fluorescent, surface mount _________

c. Incandescent _________

d. Spotlighting _________

e. Other _________ (Specify)__________________________________

2. Lighting Intensity (Specify where appropriate.)

a. Operator Work Area: ____________fc

b. Equipment Area: ____________fc

c. Maintenance Area: ____________fc

d. Storage Area: ____________fc




e. Office Area: ____________fc

f. Lavatory Area: ____________fc

g. Kitchen Area: ____________fc

h. Laboratory Area: ____________fc

i. Passageways: ____________fc

j. Other: ____________fc (Specify use)____________________

3. Emergency Lighting Requirements (Check and specify where appropriate.)

a. At Exit Doors ____________ Duration:___________________ mins.

b. In Control Room ____________ Duration:___________________ mins.

c. In Equipment Area ____________ Duration:___________________ mins.

d. Other ____________ Duration:___________________ mins.

(Specify Area): _________________________________________________________________________

I. SAFETY

1. Area Classification: Class _____________ Division ________ Group(s) _______

2. Safety Systems (Check all that apply.)

a. Smoke Detectors ____________ Areas Requiring Protection: _________

b. Flame Detectors ____________ Areas Requiring Protection: _________

c. Toxic Gas Detectors ____________ Areas Requiring Protection: _________

d. Combustibles Detectors ____________ Areas Requiring Protection: _________

e. Halon Systems ____________ Areas Requiring Protection: _________

f. Other Firefighting ____________ Areas Requiring Protection: _________

(Specify Type): _________________________________________________________________________

g. Other Safety Systems ____________ Areas Requiring Protection: _________

(Specify Type): _________________________________________________________________________

J. UTILITIES

1. Electrical Power (Check all that apply; specify data where appropriate.)

a. 12 VDC with UPS ______ Load, amps: _________ Battery amp-hours: ________________

b. 24 VDC with UPS ______ Load, amps: _________ Battery amp-hours: ________________

c. 48 VDC with UPS ______ Load, amps: _________ Battery amp-hours: ________________

d. 120 VDC with UPS ______ Load, amps: _________ Battery amp-hours: ________________

e. ___ VDC with UPS ______ Load, amps: _________ Battery amp-hours: ________________

f. 120 VAC with UPS ______ Load, amps: _________ Battery amp-hours: ________________

g. ___ VAC with UPS ______ Load, amps: _________ Battery amp-hours: ________________

h. 12 VDC (no UPS) ______ Load, amps: _________




ers,

– Ceiling– Floor– HVAC system– Gas detection system– Purging system– Fire detection system– Fire extinguishing system– Page-party system– Other communications equipment

7. Drawings showing the following:

– Location of multicable transit and bulkhead penetrations– Layout of gas detectors, smoke detectors, fire detectors and extinguish

and Halon system

i. 24 VDC (no UPS) ______ Load, amps: _________

j. 48 VDC (no UPS) ______ Load, amps: _________

k. 120 VDC (no UPS) ______ Load, amps: _________

l. ___ VDC (no UPS) ______ Load, amps: _________

m. 120 VAC (no UPS) ______ Load, amps: _________

n. 480 VAC (no UPS) ______ Load, amps: _________

o. ___ VAC (no UPS) ______ Load, amps: _________

2. Instrument Air ______ Pressure, PSIG: ______ Volume, SCFM: ___________________

Filtration, microns: ______

3. Water

a. Potable water ______ Pressure, PSIG: ______ Volume, GPM: ____________________

b. Hot water ______ Pressure, PSIG: ______ Volume, GPM: ____________________

c. Cold water ______ Pressure, PSIG: ______ Volume, GPM: ____________________

4. Sanitary Sewers

a. General Purpose Sewer ___________________ Volume, GPM: ____________________

b. Laboratory Sewer ___________________ Volume, GPM: ____________________

c. Other Sewer ___________________ Volume, GPM: ____________________

(Specify use): __________________________________________________________________________

5. Other Utilities

a. Type: _________________________________ Capacity: _________________________________

b. Type: _________________________________ Capacity: _________________________________




c-

this

nd are

ce

– HVAC system, including ducting, vents, exhausts, intakes, and central plant equipment

– Electrical distribution and plumbing

1180 Sample Control Room Design CriteriaThe scenario for this design example is as follows: A manned oil and gas prodution platform is to be designed for installation off the west coast of Cabinda, Angola, and a central control room is required. (System capacity is not stated inexample.)

1. Temperature:

Min 54°FMax 94°F

2. Humidity: 81 to 89%

3. Prevailing wind:

Direction—from southwestVelocity—

1 Hour average: 10 knots3 Second average: 15 knots

4. Classification of area where control room should be located: unclassified

5. Unusual weather occurrences: none

6. Weight restrictions: 75 tons, max.

7. Size restrictions: 57 by 34 ft., max.

8. Power availability:

120 VAC Single-phase, 60 Hz480 VAC Three-phase, 60 Hz120 VDC24 VDC

9. Water availability: sufficient

10. Air supply: sufficient

The prerequisites for the design of the central control room are also assumed aas follows:

1. Number of administrative personnel: one per 12 hrs

2. Number of technical specialists: one

3. Computer requirements: A computer is required to support the distributed control system. An operator interface CRT, a computer, and a printer interfa



er s

sign

ox-this

-

are required. Cabinets connecting the computer to the field instrumentation are located in the control room.

– Computer Console: Configuration—Six bays with an integral desk; Size—Approximately 132 in. long, 48 in. deep, and 72 in. tall; Power Consumption—Computer and CRT: 1400 watts,—Printer: 300 watts,—Disk Drive: 250 watts.

– Interface Cabinet Configuration: eight separate I/O cabinets with field terminations; four emergency shutdown (ESD) Cabinets.

– Size: I/O Cabinets—each 26 in. wide x 48 in. deep x 84 in. high; Emer-gency Shutdown Cabinets—26 in. wide x 36 in. deep x 72 in. high; PowConsumption: I/O cabinets—800 watts each; ESD Cabinets—250 watteach.

Once the Checklist for Control Room Design is completed, the control room decan begin. The following steps are recommended:

1. Locate the control room on the basis of wind direction, current direction, primity to escape routes, and proximity to the process area. For purposes of example, the control room is located in a nonhazardous area. See Figure 1100-11.

2. Establish the size of the control room by creating a layout showing all equipment with minimum or greater clearances. See Figure 1100-12.

Fig. 1100-11 Control Room Location Plan



3. Perform the architectural design, including walls, windows, ceiling, flooring, and lighting. Provide a building specification based on the above requirements.

4. Lay out the HVAC system. See Figure 1100-13.

Fig. 1100-12 Control Room Equipment Layout

Fig. 1100-13 Location of HVAC and Fire/Gas Protection Systems in Control Room



5. Lay out the fire protection and gas detection systems. See Figure 1100-13.

6. Provide room for the communications equipment (including ship-to-shore, surface-to-air, and internal communications). Locate the communications equipment required to support the operation of the control room with the plat-form or process plant, coordinating with the telecommunications group.

7. Establish the electrical load requirements of the equipment as determined in Steps 2 through 6. See Figure 1100-14 for an example calculation.

8. Establish cable and pneumatic line layouts including the location of bulkheads and multicable transits. See Figure 1100-15.

The above example only provides a general description of a control room. When actual overall system requirements are established, a detailed design and specifica-tion must be developed.

Fig. 1100-14 Electrical Load Requirements for Control Room Equipment

DESCRIPTION POWER REQD VOLTAGE UPS/PRIMARY

Computer and CRT 1,400 Watts 120 VAC Primary

Disk Drive 250 Watts 120 VAC Primary

Printer 300 Watts 120 VAC Primary

I/O Cabinets (8) 6,400 Watts 24 VDC Primary

ESD Cabinets (4) 1,000 Watts 24 VDC UPS

Lab Equipment 3,000 Watts 120 VAC Primary

Lighting 10,000 Watts 120 VAC Primary

Emergency Lighting 2,000 Watts 120 VDC UPS

Fire & Gas Detection 5,000 Watts 24 VDC UPS

HVAC System 25,000 Watts 480 VAC/3ph/60 Hz Primary

Radio System 3,500 Watts 24 VDC UPS

SUMMARYThis control room has the following power requirements from the respective power supplies:

24 VDC UPS 9,500 Watts

120 VDC UPS 2,000 Watts

480 VAC Primary 25,000 Watts

120 VAC Primary 14,950 Watts

24 VDC Primary 6,400 Watts



1190 References

1191 Model Specifications

1192 Other ReferencesNational Fire Protection Association (NFPA) Standard No. 496, Purged and Pressurized Enclosures for Electrical Equipment

Chevron Corporation, Electrical Manual, Section 300, “Area Classification.”

Chevron Corporation, Electrical Manual, Section 1200, “Lighting.”

Chevron Corporation, Civil and Structural Manual, Section 400, “Small Buildings.”

Fig. 1100-15 Typical Bulkhead Layout

SpecificationICM-MS-3651

Installation Requirements for Digital Instrumentation and Process Computers

Specification ICM-MS-1348

Shop-Fabricated Control Panels

ISA RP 12.1 Electrical Instruments in Hazardous Atmospheres.

ISA RP 60.9 Piping Guide for Control Centers.

ISA S7.3 Quality Standard for Instrument Air.


Documents

ICM1100 Control Room Design