Introduction to ASM Best Practices for Control Suite Design'

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• Introduction to ASM Best Practices for Control
  Suite Design.
• Human Reliability
• Process Performance
• Mechanical Integrity

20B PONC, USA
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Evolution of Control Rooms
1990 - 2040
1970 -1990
1940 - 1980
1900 - 1950
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1950S
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NOVA Chemicals, Corruna, Ontario, Canada
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WOODSIDE OFFSHORE PETROLEUM KARRATHA, WESTERN
AUSTRALIA
Woodside Energy Ltd., Karratha, Western Australia
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Woodside Energy Ltd., Karratha, Western Australia
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Woodside Energy Ltd., Karratha, Western Australia
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Woodside Energy Ltd., Karratha, Western Australia
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Woodside Energy Ltd., Karratha, Western Australia
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Control Room Design
This part of Decision Support - Workspace Design
Before
After
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NOVA Chemicals, Corruna, Ontario, Canada
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NOVA Chemicals, Corruna, Ontario, Canada
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Key factors which are attributed to this loss-

• People have failed to keep pace with the task
• Change requires changes in culture which can be
  difficult to achieve and measure.
• Inadequate Situational Awareness
• Inadequate collaboration in problem solving
• Demands imposed by abnormal situations

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• Designing a control room effectively is an
  extremely complex task because of the
  multifunctional nature of control buildings.
• Its a Communications Center
• Its the distribution, coordination control
  center for the plant work
• It must be suitable for 24 hour operation in 8 or
  12 hour shift system
• It is the main training facility for operators
• Its an Emergency Response Center
• Often Control Application Development Center

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• Goal is to enhance the manufacturing team
  performance in and around the control room
• Reduce the costs associated with health care
• Design factors must consider influences such as-
• comfort, health, safety, efficiency
  effectiveness of all people
• interacting collaboration in the control room
• Design principles will affect the design
  parameters for-
• architecture, lighting, acoustics, environmental
  controls
• control system (including the User Interfaces)
• workspace (including information delivery)

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• Decisions made about the control center design
  significantly effect the nature of the operations
  task themselves as well as effectiveness and
  efficiency in which the tasks are carried out.

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• Integration of ergonomics with the traditional
  functional approach enables the designers to
  define an integrated and compatible set of
  technical and organizational design criteria.
• The methodology extends the consideration of
  required functionality from the human perspective.

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• Error tolerance design
• Design solutions that inform users of the
  situation they are in
• Add back-up support via redundancy, interlocks,
  automation systems
• Interactive modification process
• Validation steps are used to improve on the design

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Centralized versus Distributed Control Rooms

• Complex Communication structure
• Variable communication depending on style
• Value of understanding team member role needs
• Console operator proximity to other team members
  - awareness
• External relationships - other shifts, customers

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Explosions and Fires

• Accidents resulting in major damage to occupied
  buildings are rare but when they occur the
  results can be tragic and disastrous.
• Hickson Welch (UK - 1992)
• La Mede Refinery Total (France - 1993)
• Philips Pasadena, Texas (USA - 1992)
• In each case 5 or more people died as a direct
  result of being in a building on a CPI site.

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Common causes

• Most fatalities in buildings resulted from Vapour
  Cloud Explosions (VCEs).
• Other types of overpressure causes, such as
  Boiling Liquid Expanding Vapor Explosions
  (BLEVEs) vessel failure chemical reaction
  runaways, should also be considered.

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Other causes

• The escape of toxic gas can also be a threat, as
  demonstrated by the Bhopal disaster (1984).
• Consider the implications of toxic release for
  people and the protection that a well designed
  and sited building can provide.
• Buildings can also provide protection against
  fire especially when wearing NOMEX coveralls.

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Prevention of Abnormal Situations

• The major effort of operating companies should be
  directed to prevention of events which trigger
  major accidents. (ASM)
• This is in keeping with the principles of
  Responsible Care which much of the chemical
  industry has embraced.

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Responsible Care

• Inherent Safety should be applied, e.g. the
  amount of hazardous material should be minimized
  and the number of people exposed to chemical
  plant hazards of the type referred to should be
  minimized.
• To mitigate the hazards that cannot be removed,
  Hazard Identification Techniques Hazard
  Management Practices should be adopted.

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Building Compromises

• The closer the building to the plant the more
  effective the occupants could be in operating and
  maintaining the plant by being closer to the
  hardware they manage or the people with whom they
  interface. It is arguable that there is less
  likelihood of there being an accident due to
  better communications between key groups of
  people.

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• The closer the people are to the plant the higher
  the risk they run of being exposed to the
  consequences of the hazards of the plant should
  these consequences be realized.
• To balance these hazards it is important to
  consider the protection given to the people by
  the building they occupy. The closer to the
  hazards the more protection the building must
  provide and hence, the more it will cost.

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• The criteria for risk acceptability are the
  responsibility of individual companies and are
  specific to their operations.
• Advice is given by the Chemical Industries
  Association - Chemical Industry Safety, Health
  and Environment Council (CISHEC) UK.

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International Draft Standard from ISO

• Clarification
• Analysis definition
• Integrated Concept proposal
• Design proposal
• Operational Feedback

ISO/CD 11064-1 Ergonomic design of control
centers Part 1 Principles for the design of
control centers
See page 8 Control Center Workspace Design
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• A Prototypical Ergonomic System Design Approach
• Problem Definition Shared Vision
• System Description Task Analysis
• Task Allocation Job Roles
• Control Center Detailed Design
• Operational Feedback

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• Problem Definition Shared Vision
• Clarify operational goals, and identify design
  constraints
• Clarify goals background requirements in the
  following areas-
• functional goals
• safety security
• operational control
• ergonomic, organizational, company policy,
  company standards, technical constraints,
  resource constraints, operational experience.

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• Task Analysis
• Information and action requirements
• Collaborative and shared workspace activities
• Multitasking requirements
• Process Analysis
• Process characteristics
• Control strategy
• Ergonomics
• Physical worksurfaces (tables, chairs)
• Environment (climate, acoustics, lighting)
• Positioning of information and control artifacts
• Relations between workstations and workplaces

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• System Description Task Analysis
• Develop and integrate a set of validated task
  requirements based on an understanding of the
  process and production goals.
• Define the technological system from the
  perspective of the process flow, control system,
  the production responsibilities and constraints.

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• If the design will be based on an existing HMI,
  then the team should develop an explicit
  description of the HMI-
• the work organization
• dimensions of the control room console layout
• an instrument control loop count for each
  console

Define- steady state, normal transient operation
(startup, shutdown), emergency/abnormal operation.
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• The first step in task analysis is to develop a
  representative set of scenarios across the
  operational modes.
• The task analysis should involve collection of
  both objective (observations) and subjective
  measurements (interviews with operators on roles
  in current situations wishes for future system)

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• The data collection should pay attention to key
  factors that impact operator workload effective
  performance.
• Links between communication technical data for
  the task
• adequacy, timeliness accuracy of the data for
  the task
• personnel preparedness for technology upgrade

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• Task Allocation Job Roles
• The system description task analysis provides a
  description of the current control design
  indications of its strengths weaknesses.
• At this point, the team needs to shift thoughts
  to improving the global detailed allocation of
  tasks.

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Task Allocation Job Roles

• Define the number types of jobs to be carried
  out by people automation.
• Global task allocation
• combining tasks into jobs
• define operator competencies
• definition of the work organization
• Staffing levels should be based on organization,
  complexity, continuity, quantitative dynamic
  aspects of the process

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• Functional Conceptualization
• Develop Functional Conceptualization Design
  Requirements for the control center.
• space allocations for control equipment
• work surface requirements
• functional links between areas
• supporting facilities such as washrooms
  kitchens
• functional conceptualization design review

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• Control Center Detailed Design Specification-
• control center arrangements
• control room layout
• workstation layout dimensions
• display controls design
• environmental design requirements
• operational managerial design requirements

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Configuring general workstation groupings

• Sharing workstation equipment
• Sharing off-workstation displays
• Direct eye contact
• Verbal communications
• Low noise interference
• Message passing
• Collection and delivery of paperwork
• Teamwork support
• Separation of groups
• Equipment access for maintenance

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• Bring the big picture view back to control room
• View Lost with Advent of DCS
• Managers, senior and outside operators quickly
  know where plant is
• Reduce the stress of console operator during an
  upset
• Allows others in the control room to gather unit
  status without interrupting the console operator.
• Provide more mobility to console operator
• Keep an eye on units when assisting the adjacent
  console operator.
• Keep an eye on units when attending tool box
  meetings, etc. in control room.
• Keep an eye on units when working at work
  station.
• Keep an eye on units when exercising or eating
• Allow console operator to make timely decisions
• Quickly see the status of units on the adjacent
  console.
• Enable wide view of systems in an incident
• (Fire / Gas)

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• Minimize unnecessary traffic in control room
• Concentrate critical operations personnel near
  control room
• Provide view into control room for critical
  personnel
• Improve traffic flow of people within control
  building
• Keep control engineers close to control room
• Provide a good reflective lighting plan
• Eliminate glare on operators screens
• Provide dedicated task lighting where required
• Minimize unnecessary noise in control room
• Provide acoustical treatments - carpet / paneled
  walls
• Place noisy printers in another room

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Physical Space Considerations

• A heuristic value for planning floor-space
  allocation is to allow for 10 to 15 m2 per
  working position with a minimum of not less than
  9 m2.
• Square, circular and hexagonal spaces offer the
  maximum flexibility as far as the arrangement of
  functional groups and offer the potential of
  maximizing the number of links between groups. In
  contrast, long narrow spaces unduly restrict link
  options. Adversely, the circular and hexagonal
  shapes are more likely to concentrate noise.

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• Space provisions should consider requirements
  over the full planned life-span, a general rule
  of thumb recommendation is to allow for 25
  additional space for expansion.
• Particular consideration should be given to
  adequate circulation areas where shift changeover
  is protracted and two shifts may be present at
  same time.
• For vertical space provisions, a slab to slab
  height should be a minimum of 3 m to allow for
  false floors and ceilings, indirect lighting and
  off-workstation displays.

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• Walkways for general traffic must be at least 140
  cm. (56 in.). Avoid walkways through the middle
  of the operational area.
• A single main entrance and exit offers the best
  solution for security and staff control. However,
  other emergency exits will need to be provided
  (See ISO Report ISO 11064-3, 1997 for formulas
  to calculate emergency and non-emergency exit
  openings).

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• Decisions on control room windows, and their
  design and treatment, should be based on their
  operational use (See ISO Report ISO 11064-3,
  1997 for extensive treatment of window use).
• Windows in control rooms should not be a source
  of glare or disturbing reflections, especially on
  work surfaces and displays some ways of doing
  this are by ensuring that windows are suitably
  oriented and/or recessed with splayed reveals.

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The Control Room Suite-

• Facilities
• meeting or conference room,
• equipment room,
• printer, copier and mailroom,
• engineering, planning, and management offices,
• maintenance room,
• application development room,
• exercise room
• shower and locker rooms

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• washrooms,
• relaxation room (recovery room),
• kitchen,
• janitor/cleaning supply room,
• training room,
• library,
• permitting area,
• mud room (entry way).

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• General Principles of Workstation Design
• Aim for comfortable and varied working postures
  and dynamic work of moderate intensity involving
  large muscle groups. Avoid static postures.
• Consider the possibility of rest. The working
  posture and need for the body to rest during work
  are noted and the need for resting surfaces, e.g.
  in the form of chairs, should be specified here.

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• Avoid extremes of the range of motion at any
  joint by keeping joints in middle third of range
  of movement. Work within the reach envelope and
  generally avoid awkward postures.
• Especially avoid ulnar deviation of the wrist
  greater than 10 degrees, neck extension, or
  extreme neck flexion.
• Avoid movements involving maximum effort.

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• Avoid repetitive movements, especially combined
  with any of the above.
• Rationale workplace layout involves organizing
  work by importance, frequency, group related
  functions, and compatible sequences.

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• Today we talk about human factors!
• Tomorrow we will be talking about Human Centered
  Design.
• We need to understand the impact of our design
• Shift work, rotation, hours, facilities
• User Interface
• Alarm System
• Design of control room
• Design of Consoles
• Use of Procedures Checklists
• Training

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User Centered human-factor design

• User-Centered Design
• Semantics of user interface/workspace
• Defining the meaningful dialog in the
  human-machine system interactions
• Emphasis on user- task- modeling to define
  appropriate design features

• Human-Factored Design
• Syntactics of user interface/workspace
• Defining the consistent, human friendly grammar
  for dialog in the human-machine system
  interactions
• Emphasis on human capabilities and limitations,
  i.e., memory, selective attentions, calculation
  skills, reading skills

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• User-Centered Design
• Impacts functional definition of workspace and
  functional roles
• User interface/workspace
• Functional decomposition of displays
• Navigation scheme to access plant information,
  displays and procedures
• Definition of information content

• Human-Factored Design
• Impacts appearance and arrangement of the
  workspace
• User interface/workspace
• Display layout and density
• Use of visual coding
• Font conventions

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Best Practices recognized by ASMC