Control Room Design Service Yokogawa

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


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– Service definition

– Features

– Workflow

– Schedule

Introduction


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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)


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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


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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


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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


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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


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Locker room

CanteenRest room

Visitors room

Stairs

Layout in Consideration for Visitors


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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.


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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


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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


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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


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Improve

Prepare a conceptual design that includes as follows:

– Design concept (document)

– Room layout (figure)

– Grounds of layout (document)


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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


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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


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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

Documents

Control Room Design Service Yokogawa