1100 Control Room Design

1100 Control Room Design Abstract This 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

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1110 Introduction

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1111 Definitions of Control Room Types 1120 Background

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1121 Engineering and Coordination 1130 Design Parameters

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1131 Environmental Parameters 1132 Physical Parameters 1133 Utilities 1140 Prerequisites and Procedures

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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

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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

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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

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1171 Checklist for Control Room Design 1172 Final Documentation 1180 Sample Control Room Design Criteria

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1190 References

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1191 Model Specifications 1192 Other References

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1110 Introduction This 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 expertise to supplement guideline recommendations.

1111 Definitions of Control Room Types For 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 Room The 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 monitoring 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 Room The 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 Coordination The 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 appropriate

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 Parameters The 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 relative 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

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Weight and size restrictions for major equipment or modules to be installed at the site, and access by transport and cranes

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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

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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 Documentation Preliminary 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 Data 1.

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 Data 1.

Personnel requirements—operating, technical, and administrative – – – –

2.

Control, shutdown, and environmental monitoring systems requirements – – –

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Changing room Lavatories Lunchroom Maintenance area

Physical size, layout, and location Power consumption Interface requirements

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1144 Design Procedure Sequence 1.

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 Design The systems that may be included in the design of a control room are air-conditioning 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 Filtering An HVAC system is required in any control room containing personnel or temperature-sensitive electronic equipment. The HVAC system may also serve as the pressurization 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 Systems Although the Company does build purged and pressurized control rooms and buildings, this is done primarily to prevent air contamination. Such rooms and buildings are normally located in unclassified areas only, an exception being offshore platforms. 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:

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

•

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

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API RP 505 Classification of Locations for Electrical Installations at Petroleum 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”

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Electrical Manual, Section 300, “Area Classification”

1153 Utilities The utilities required for most control room installations include electrical power, instrument-quality compressed air, and potable water and drain systems.

Electrical power systems Control room electrical power requirements can include any or all of the following: 1.

12 VDC, 24 VDC, or 120 VAC, all with UPS, for instrumentation and control systems

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 systems

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

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

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

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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 Systems Gas 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 system The in-plant communications system enables communications between field operators, local control rooms, and the central control room. Equipment selected for this application can include sound-powered phones, local telephone system extensions, intercom sets, radios, or combinations of two or more types of equipment. In-plant systems can also include the ability to announce plant emergencies such as fire, accidents, and evacuation signals. System design should limit traffic to that which is of interest to a single plant area.

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

Coordination The design of these systems should be coordinated with the Telecommunications Department.

1160 Design Concepts 1161 General Considerations The following criteria should be considered for control room designs.

Safety considerations Safety considerations should include area classification, location in relation to classified areas, fire and gas protection, blast protection, and proximity to escape routes.

Area classification The control room is preferably located in an unclassified area. This requirement is extremely critical for both personnel and electronic equipment. If a control room

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

Location The 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 protection Fire 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 routes The 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 considerations The 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 implementation of procedures to minimize RFI generation near sensitive instruments.

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Accessibility and communications A 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 automated, a supervisory control and data acquisition (SCADA) system may be required for data communications to a manned control room.

Ambient nose considerations Control 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 facilities General 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 facilities 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 plants These locker and shower facilities should be designed so that personnel are provided with a “dirty” changing area having direct access to the showers and separated from the clean dressing areas with a walk-through passageway that can be used when arriving personnel change into workclothes.

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

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General requirements The 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 doors Control 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.

Lighting The 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.

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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 orderly shutdown of the facility in the event of a power failure, and permit safe exit from the control room. Fluorescent lighting fixtures are recommended for most applications to achieve the normal lighting levels required. This type of fixture reduces glare and power consumption. Ceiling, wall, and floor reflectance can also be utilized to obtain a glare-free lighting environment.

Ceiling design The 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 control room ceiling. The desirability of a suspended ceiling is determined by whether the space above it will 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, is recommended for control rooms housing primarily electronic instrumentation, because this configuration allows for substantial future changes to the instrumentation and its connecting cabling. A flat suspended ceiling with acoustical tiles permanently attached to the false-work can provide space for routing ducting, utilities, and cabling, but lacks flexibility for installing instrumentation cabling additions. Both configurations of suspended ceiling allow for installation of flush-mounted fluorescent lighting fixtures and the easy reconfiguration of lighting fixture layout as 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 the equipment planned for the control room, and should be a minimum of 9 feet; use of a greater height adds to the esthetics of larger control rooms.

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

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Fig. 1100-2 Reflected Ceiling Plan

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

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A raised floor in conjunction with a suspended ceiling should be considered for electronic equipment. Both floor and ceiling then provide space for cable interconnection 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 Requirements for Digital Instrumentation and Process Computers.

1163 Control Room Environment The 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 Design Design 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 maintain the room internal pressure. If the control room is not pressurized, and if the walls are not required to be fireresistant 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

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Fig. 1100-4 Multicable Transit (Courtesy of Nelson Fire Stop Products) COMPRESSION BOLT When tightened, the bolt applies pressure to the compression plate sealing the grooved insert modules around the cables.

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 available 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 continuous seal even if cable jackets disintegrate. The entire assembly within each frame is locked in position to prevent dislodgement and the spread of fire and the products of combustion.

END PACKING—STANDARD End 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—SPECIAL The special end packing assembly serves the same purpose as the standard and is used when the transit frame is accessible from only one side. COMPRESSION PLATE The compression plate acts as a pressure plate above the internal assembly. STAY PLATES Stay 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 MODULES Grooved 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.

TRANSIT FRAME The 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.

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

RTV-106 SEALER For 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.

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FILL-IN INSERT STRIPS Used 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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Fig. 1100-5 Typical Bulkhead Connections

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 Panels Two factors affect control room arrangement: space required and use of conventional panels or shared-display (CRT) systems. Typical arrangements for conventional and shared-display systems and associated equipment are shown in Figures 1100-7, 1100-8, and 1100-9.

General considerations for operator work areas The 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 nonoperational work areas. Appropriate communications to the operator work station should be provided.

Clearances The 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 electrical code, whichever is greater

•

Overhead clearance for panels: 1 foot

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

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

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

Color considerations A 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.

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

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Fig. 1100-8 Offshore Control Building: Electrical Plan

1. NAV AID BATTERY RACK

21. 125 VDC 30A MAIN 3 2

41. GAS DETECTION PANEL

2. 125 VDC BATTERY RACK

22. 125 VDC MAIN BREAKER PANEL

42. GAS DETECTION PANEL

3. 125 VDC BATTERY RACK

23. 480 VAC POWER DISTRIBUTION PANEL

43. TRANSFORMER 4160/480 VOLT

4. 24 VDC BATTERY (CONTROL) RACK

24. 208 VAC LIGHTING PANEL

44. WATER CHILLER UNIT #1

5. 24 VDC BATTERY (GENERATOR) RACK

25. A/C DISTRIBUTION PANEL

45. WATER CHILLER UNIT #2

6. 125 VDC BATTERY RACK

26. A/C DISTRIBUTION PANEL

46. WATER FOUNTAIN

7. 24 VDC DISTRIBUTION BOARD

27. 480V SWITCHGEAR

8. 24 VDC U.V. CONTACTOR

28. 480V MCC

47. WALL MTD HAND SET/SPEAKER AMPLIFIER

9. NAV AID BATTERY CHARGER

29. 125 VDC HALON LATCHING RELAY

48. LINE BALANCE ASSEMBLY

10. 24 VDC CONTACTOR FOR SOLAR GENERATOR

30. 4160 SWITCHGEAR

49. MULTI-TONE GENERATOR

11. 24 VDC BATTERY CHARGER 12. 24 VDC BATTERY CHARGER 13. 24 VDC BATTERY CHARGER 14. 24 VDC BATTERY CHARGER 15. 125 VDC EMERGENCY LUBE PUMP STARTER 16. 125 VDC DISTRIBUTION BOARD 17. 24 VDC CONTACTOR (SOLAR LUBE) 18. 125 VDC BATTERY CHARGER 19. 125 VDC BATTERY CHARGER

31. "C" TRAIN COMPRESSOR CONTROL PANEL 50. CONE SPEAKER 51. DESK TOP HANDSETS/SPEAKER 32. CENTRAL CONTROL PANEL AMPLIFIER 33. "D" TRAIN (FUTURE) 52. AMPLIFIER 34. INSTRUMENT AIR PANEL 53. P/C TERMINAL 35. 3 INVERTERS (STACKED) 54. 45 KVA TRANSFORMER 36. GENERATOR PANEL #1 55. 24 VDC 70 AMP MAIN BREAKER 37. GENERATOR PANEL #2 56. 125 VDC 100 AMP MAIN BREAKER 38. PLC LOGIC PANEL 57. 24 VDC 70 AMP MAIN BREAKER 39. FIRE DETECTION PANEL 58. 24 VDC STARTER (SOLAR LUBE) 40. GAS DETECTION PANEL 59. U.V. DETECTION PANEL

20. 125 VDC U.V. CONTACTOR

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

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Clearances The designer should maintain the same minimum clearances for operations and maintenance access to non-console equipment as described in Section 1165. Additional 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 considerations Normal lighting considerations (see Section 1162) are usually acceptable. However, a major difficulty is the glare problem on video displays. Glare reduction techniques 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 Equipment As 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 minimize 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 planned to avoid interference or difficulty in installing and maintaining the particular type of equipment. Batteries for supplying standby power to control systems, emergency lighting (except for self-contained emergency lighting packs or exit signs), and communications systems should be housed in a separate room provided with adequate ventilation to prevent the accumulation of hydrogen gas generated by battery charging.

1168 Local Control Room Design Concepts Local control rooms may be manned or unmanned, depending on the application. Usually, 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 of the overall process. Technically, little or no attention is required for personnel comfort in the design of an unmanned local control room. However, for a number of reasons (e.g., protection of equipment, declassification of the area to permit the use of less costly instrumentation, and comfort of operating and maintenance personnel), some unmanned local 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 Concepts The central control room is normally equipped to monitor and control process functions 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., charts, ink, run sheets, etc.)

Highly flammable, volatile, or toxic materials should not be permitted in the control room. If laboratory facilities are provided within the control room building, they should be provided with separate outside entry doors and be furnished with an independent HVAC system or with window-mounted air-conditioners, as discussed previously in this guideline.

1170 Checklist and Final Documentation 1171 Checklist for Control Room Design The checklist shown in Figure 1100-10 lists the data required for sizing, constructing, and providing accessories and utilities for a control room. Additional data which amplifies on these requirements may be appended to this checklist.

1172 Final Documentation The following documentation should be created: 1.

Control room location plan

2.

Control room layout drawings (showing floor plans and equipment elevations)

3.

Layout drawings for pneumatic tubing and electrical power and signal cables

4.

Area lighting analysis

5.

Lighting layout drawing

6.

Specifications for the following: –

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Building walls

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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.)

Type

Size (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-Mounted Control Panel

_______

________

______

______

______

______

______

6. Printer

_______

________

______

______

______

______

______

a. ____________________

________

______

______

______

______

______

b. ____________________

________

______

______

______

______

______

c. ____________________

________

______

______

______

______

______

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:

_______________________________________________________

7. Other (Specify):

C. SIZE REQUIREMENTS 1. Floor Area:

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Fig. 1100-10 Checklist for Control Room Design (2 of 5)

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,

4. Air Purification

_______

Airborne Contaminants:______________________________

5. Pressurization

_______

6. Sanitary Facilities

_______

7. Noise Abatement

_______

Ambient Noise Level:

8. Other

_______

(Specify)_________________________________________

____

_____

R.H. at ___°F

dBA

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

_________

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Fig. 1100-10 Checklist for Control Room Design (3 of 5) 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)

a. Interior Surfaces (Type)

_________

(Color)

_______________________________

b. Exterior Surfaces (Type)

_________

(Color)

_______________________________

3. Finish

G. CEILING 1. Construction (Check all that apply.) a. Fire Resistant

_______

b. Insulated

_______

c. Suspended

_______

d. Noise resistant

_______

e. Other

_______

2. Finish

Specify type:

T-rail__

Plenum height:

___ in.

Permanent______________

(Specify)________________________________________________

(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

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Fig. 1100-10 Checklist for Control Room Design (4 of 5) 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) _______

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: _________

2. Safety Systems (Check all that apply.)

(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: _________

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

2.

3.

4.

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: _________

Instrument Air

______

Pressure, PSIG: ______

Volume, SCFM: ___________________

Filtration, microns:

______

Water a. Potable water

______

Pressure, PSIG: ______

Volume, GPM: ____________________

b. Hot water

______

Pressure, PSIG: ______

Volume, GPM: ____________________

c. Cold water

______

Pressure, PSIG: ______

Volume, GPM: ____________________

a. General Purpose Sewer

___________________

Volume, GPM: ____________________

b. Laboratory Sewer

___________________

Volume, GPM: ____________________

c. Other Sewer

___________________

Volume, GPM: ____________________

Sanitary Sewers

(Specify use): __________________________________________________________________________ 5.

Other Utilities a. Type: _________________________________

Capacity: _________________________________

b. Type: _________________________________

Capacity: _________________________________

– – – – – – – – – 7.

Drawings showing the following: – –

Chevron Corporation

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

Location of multicable transit and bulkhead penetrations Layout of gas detectors, smoke detectors, fire detectors and extinguishers, and Halon system

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– –

HVAC system, including ducting, vents, exhausts, intakes, and central plant equipment Electrical distribution and plumbing

1180 Sample Control Room Design Criteria The scenario for this design example is as follows: A manned oil and gas production 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 in this example.) 1.

Temperature: Min 54°F Max 94°F

2.

Humidity: 81 to 89%

3.

Prevailing wind: Direction—from southwest Velocity— 1 Hour average: 10 knots 3 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 Hz 480 VAC Three-phase, 60 Hz 120 VDC 24 VDC

9.

Water availability: sufficient

10. Air supply: sufficient The prerequisites for the design of the central control room are also assumed and are as follows:

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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 interface

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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; Emergency Shutdown Cabinets—26 in. wide x 36 in. deep x 72 in. high; Power Consumption: I/O cabinets—800 watts each; ESD Cabinets—250 watts each.

Once the Checklist for Control Room Design is completed, the control room design can begin. The following steps are recommended: 1.

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

Fig. 1100-11 Control Room Location Plan

2.

Chevron Corporation

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

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Fig. 1100-12 Control Room Equipment Layout

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

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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 platform 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.

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

POWER REQD

VOLTAGE

UPS/PRIMARY

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

Computer and CRT

SUMMARY This 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

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 specification must be developed.

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Fig. 1100-15 Typical Bulkhead Layout

1190 References 1191 Model Specifications Specification ICM-MS-3651

Installation Requirements for Digital Instrumentation and Process Computers

Specification ICM-MS-1348

Shop-Fabricated Control Panels

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

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.”

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