Control Room Design

Control room design provides operation environment with maximum work efficiency

Yokogawa Electric Corporation

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

Agenda

Introduction
What is Control Room Design? Typical benefits

Best practices Consulting service

Service definition Features Workflow Schedule

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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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) Working environment Automation systems (Operation, Monitoring, Management) Business policy, Business strategy

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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Typical Steps toward Control Room Construction

Typical steps toward control room construction

Large screen position

Constructed control room

Layout planning
<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

Console design

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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. ISO 11064 Ergonomic Design of Control Centers Shell Human Factors Engineering - HMI & Control Room Design

Symbolization of clients company policy

Stance on care for employees Production strategy (cost center or profit center) Symbolic presentation to visitors
<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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Best Practices

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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Layout based on Business Workflow

Shift Manager Room To polymer plant
Smoking room Refresh room Intelligent communication room Training simulator room Daily maintenance management room

Utility monitoring board Field staff room Gas detector Aromatics Utility Polymers

To aromatics plant

Ethylene Side room Butadiene Shift manager Room

To ethylene plant
Planning Room Supply room Ethylene Accounting & Reporting Staff Maintenance Staff Utility

Workflow-based Location

Operation Butadiene Aromatics Shift manager

Instrumentation room

Planning
<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

Accounting Reporting

Maintenance

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Overhead View

Island B Island A Chemical laboratory

Island C

Island D Visitors room

Canteen Locker room

Rest room

Stairs

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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Layout in Consideration for Visitors

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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Dimensional Drawing

Canteen

Training Room

Traffic Line
Staff Room Staff Room

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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Console Layout based on Ergonomics & Maintainability

The type of console grouping is referred from ISO 11064 Part3 in which Yokogawa contributed.

Console layout in consideration for hot cut over (DCS migration under plant operation)

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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Color Coordination

Point of color coordination

To provide comfortable work environment To reduce the tiredness of eyes and bodies To increase work efficiency
Sober atmosphere Sense of stability Brain activation Energetic atmosphere

Warm Color Coordination

Cool Color Coordination

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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Large Screen Setting & Glare Study (not in this phase)

Large screen

View Point 1

View Point 2

Shift superintendent

Board operator

Temporary access

Study for setting angle of large screen

View Point 1

View Point 2

Study for glare / reflection

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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Lighting and Ergonomic Design (not in this phase)

Range of neck movement

Limit of the visual field

Limit of the colored visual field Range of eye motion

Lighting design (including illumination distribution)

Range of arm motion

Ergonomic design for console

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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Oil Refinery

1996
Shin-nihon Oil / Osaka Refining Center
Control room (1F)

Visitors room (2F)

Visitors room (2F)

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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Gas Supply

2004
Osaka Gas Co., LTD. / Senboku Plant

Front panel; Large screen (70 inch x2), Electric Graphic Panel, Disaster prevention Graphic Panel, Emergency SW, ITV ( 21 inchCRTx6),Annunciator, Digital Indicator

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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Water Treatment

2004
Water Works Bureau of Hurue Water Purification Plant

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.

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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Gas Supply

2001
Toho Gas Co., LTD. / Midorihama Plant

Front panel; Large screen (50 inch Multi x6), Emergency SW ITV ( 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.

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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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
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)

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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Features
Yokogawas 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

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
<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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History of CCR Design Work

1975 Sales release of worlds 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 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) service 2000 Sales release of original desk FDDS 2003 Sales release of information interface board ECCR Launch of CCR design consulting service 2005 Sales release of original desk Pride

More than 500 projects experiences

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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Workflow
Define
Define target for control room design

Measure
Use questionnaire to acquire customer information

Analyze
Analyze clients' needs based on acquired information

Improve
Prepare conceptual design

Control
Issue and introduce conceptual design Advise on next activities

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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Define

Define target for control room design

e.g. Comfort Safety Functionality Innovation

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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Measure

Use questionnaire to acquire customer information

Plant Building System Project Operation

Survey existing control room (where possible)

Control room layout Traffic flow
Operator console layout Human machine interface Panel Fixtures and furniture
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<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

Example of questionnaire
Category 1. Room Dimension Location Aspect, Direction Flooring Window Door Building codes and standards Religious custom/National backgrounds 2. Systems Configuration and access frequency Network structure and necessary performance 3. Operation Ladder Official responsibility Operational state Operational shift, rotation Business workflow by operational state Number of people per shift Number of people per operational state Meetings 4. Project Purpose of construction/renewal Project organization chart 5. Others Timing of system enhancement/migration Visitors
<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

Considerations

Purpose

Examples

Accessibility to a target plant Lighting and anti-glare Networking and lighting Lighting and anti-glare Accessibility to a target plant Compliance with standards Comfort Optimal system/desk location Optimal system/desk location Optimal system/desk location Optimal system/desk location Optimal system/desk location Optimal system/desk location Optimal system/desk location Optimal system/desk location Optimal system/desk location Meeting room design Logical planning Efficient hearing Space-consuming Construction of visitor room Page 27 Purpose, frequency, duration, head-count Control room consolidation, System migration Foreman 1, board 6, field 4 Type (pit, free access), height of ceiling w/ or w/o, location, size Location, Number, Size (for system installation) ISO 11064 Ergonomic Design of Control Centers Prayer space, color preference DCS (Console, Controller), SIS, PC, Workstation, Panel Proprietary bus, Ethernet Foreman, board, field, staff Supervision, operation, field works Normal, emergency, transition, start-up, shut-down 3 shift, 4 rotation

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

Island B Island A Chemical laboratory

Island C

Island D Visitors room

Canteen Locker room

Rest room

Stairs

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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Control

Issue and introduce a conceptual design Advise on next activities

e.g. Basic design Detailed design Manufacturing Construction

Next Activities
<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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Schedule

Step D M M A A I I C

Activity Target setting Prepare the answers to questionnaire Comprehend the provide information Survey existing control room Analyze requirements by interview Develop a conceptual design Customer support by telephone and/or e-mail Issue and introduce a conceptual design

Yoko gawa

Client

Site/ Office S S O

1st month

2nd month

S S O O S

Yokogawa covers this service in a total period of two months maximum. DMAIC cycle is executed once in one Control Room Design Service.

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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Thank you very much for your attention

<IA-PESC-08-093> Copyright Yokogawa Electric Corporation <April 2008>

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