EEMUA PUB NO 201-2010 Process plant control desks utilising Human-Computer Interfaces (Edition 2)《制炼厂控制台用人机界面(第2版)》.pdf

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1、 Process plant control desks utilising Human-Computer Interfaces A guide to design, operational and Human-Computer Interface issues PUBLICATION 201 Edition 2 Released by IHS. NOT FOR RESALE THE ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION Process plant control desks utilising Human-Computer

2、 Interfaces A guide to design, operational and Human-Computer Interface issues PUBLICATION 201 Edition 2 Copyright 2010 The Engineering Equipment and Materials Users Association. A company limited by guarantee. Registered in England. Company number 477838. ISBN 978 0 85931 176 2 Imprint reference 03

3、-2010 10-12 Lovat Lane London EC3R 8DN Telephone: +44 (0)20 7621 0011 Fax: +44 (0)20 7621 0022 E-mail: saleseemua.org Website: www.eemua.org EEMUA Publication 201 - Process plant control desks utilising Human-Computer Interfaces EEMUA ii ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION The Engi

4、neering Equipment and Materials Users Association, more commonly known as EEMUA, is a European non-profit membership Association helping companies that own or operate industrial facilities - the users of engineering equipment and materials. EEMUA aims to improve the safety, environmental and operati

5、ng performance of industrial facilities in the most cost-effective way, thereby demonstrating and pursuing leadership in asset management. EEMUA Members pursue these aims through collaboration for mutual benefit, sharing engineering experiences and expertise and by promoting their distinct interests

6、 as the users of engineering products. Specifically, the aims of EEMUA Member companies are achieved by: providing the organisation within which networking, information sharing and collaboration on non-competitive technical matters can take place; influencing the way written regulations are interpre

7、ted and applied in practice; presenting and promoting Members views, and encouraging the application of good, sound engineering practices; developing user guides, specifications, training and competency schemes; facilitating Members participation in national and international standards making; influ

8、encing relevant national and European legislation and regulations. Formed in 1949 as the Engineering Equipment Users Association, and re-named in 1983 (as a result of taking over the materials association, OCMA), EEMUA has for more than fifty years given companies that own and operate process plants

9、, power stations and other significant industrial facilities, a collaborative voice in addressing technical and engineering related issues that impact on good integrity management and asset management practices. The Association is open to companies of all sizes that meet its engineering user criteri

10、a. Further details of current Members of EEMUA is available on the Associations website, www.eemua.org. EEMUA activities often lead to the production of publications. These are prepared for Members use and are often offered for sale as well. A list of EEMUA publications for sale is given at the end

11、of this Publication. The full list is also on the Associations website, including details of on-line shopping facilities. To enquire about corporate Membership, write to enquirieseemua.org or call +44 (0)20 7621 0011. EEMUA Publication 201 - Process plant control desks utilising Human-Computer Inter

12、faces EEMUA iii ABOUT THIS PUBLICATION Legal Aspects All rights, title and interest in this Publication belong to EEMUA. All rights are reserved. No part of this Publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means: electronic, mechanical, photocopy

13、ing, recording or other, without the express prior written agreement of the EEMUA Executive Director. Infringement of copyright is illegal and also reduces the Associations income thereby jeopardising its ability to fund the production of future publications. It has been assumed in the preparation o

14、f this Publication that: the user ensures selection of those parts of its contents appropriate to the intended application; and that such selection and application is correctly carried out by appropriately qualified and competent persons for whose guidance this Publication has been prepared. EEMUA a

15、nd the individual members of the Work Group that prepared this EEMUA Publication do not, and indeed cannot, make any representation or give any warranty or guarantee in connection with material contained herein. EEMUA and the individual members of the Work Group that prepared this EEMUA Publication

16、expressly disclaim any liability or responsibility for damage or loss resulting from the use or reliance on this Publication. Any recommendations contained herein are based on the most authoritative information available at the time of writing and on current good engineering practice, but it is esse

17、ntial for the user to take account of pertinent subsequent developments and/or legislation. Any person who encounters an inaccuracy or ambiguity when making use of this Publication is asked to notify EEMUA without delay so that the matter may be investigated and appropriate action taken. Consultatio

18、n and Feedback EEMUA encourages constructive comments on this Publication from both Members of the Association and others. Comments should be sent on the standard feedback form, a copy of which is provided towards the end of this Publication. An electronic version of the feedback form is available f

19、rom EEMUA - e-mail your request for a copy to enquirieseemua.org, telephone your request to +44 (0)20 7621 0011, or download the form from the EEMUA website at www.eemua.org. Submit comments by e-mail (preferred) or post. Comments are considered by the relevant EEMUA Technical Committee and may be i

20、ncorporated in future editions of this Publication. New editions are publicised on the EEMUA website. Cover photograph of Tilbury Power Station, 2010 reproduced with kind permission of RWE npower. EEMUA Publication 201 - Process plant control desks utilising Human-Computer Interfaces EEMUA iv EEMUA

21、Publication 201 - Process plant control desks utilising Human-Computer Interfaces EEMUA v Contents Foreword ix Scope . xiii Definitions xv 1. Introduction 1 1.1 What is a HCI system? . 1 1.1.1 “Hard” Control Desks 1 1.1.2 “Soft” Control Desks First Generation . 2 1.1.3 “Soft” Control Desks Second Ge

22、neration . 3 1.1.4 The Challenge 3 1.2 Key Design Principles. 4 1.3 HCI Roadmap . 7 2. Control Room 9 2.1 Control Room Design Factors 9 2.2 Abnormal Situation Handling 11 2.3 Communications . 11 2.4 Control Room Noise . 12 2.5 Layout of Physical Screens . 12 2.6 Large Screens 13 3. Operator 15 3.1 R

23、ole of the Operator 15 3.2 Type of Process 16 3.2.1 The Continuous Process 16 3.2.2 The Batch Process 16 3.2.3 The Hybrid Process . 17 3.3 Automation 17 3.4 Manning Levels and Multi-unit Operation 18 4. HCI 19 4.1 Define the System Requirements 20 4.1.1 Physical Screens 20 4.1.2 Large Screens 22 4.2

24、 Develop and Review HCI Specification 23 4.2.1 Key Items . 23 4.2.2 Display Specification . 25 4.3 Abnormal Situation Handling 26 4.4 Technology 26 4.5 Windowing . 27 4.6 Navigation Techniques . 27 4.7 Information Access and Graphics . 29 4.8 Types of Graphics . 30 5. Training . 31 5.1 Competency As

25、sessment 31 5.2 Simulators . 31 6. Maintenance 33 6.1 Reliability/Redundancy/System Failure . 33 6.2 Lifecycle 34 6.3 Security . 34 EEMUA Publication 201 - Process plant control desks utilising Human-Computer Interfaces EEMUA vi Appendix 1 Roadmap (Development Process) . 37 A1.1 Control Room - Revie

26、ws . 38 A1.2 Operator - Reviews 39 A1.3 HCI - Reviews . 41 Appendix 2 Engineer Survey Form . 42 Appendix 3 Operator Survey Form 45 Appendix 4 Operator Task Review Questionnaire 48 Appendix 5 Example Refurbishment Design Strategy 52 Appendix 6 Control Room Noise 54 A6.1 Acceptable Noise Levels . 54 A

27、6.2 Sources of Noise . 54 A6.3 Control of Noise 55 Appendix 7 Conceptual Process Models . 56 A7.1 Continuous Process 56 A7.2 Batch Process . 59 A7.3 Hybrid Process 61 Appendix 8 Graphic Design . 65 A8.1 Getting Started . 65 A8.2 Overriding Principles 65 A8.3 Basic Design . 66 A8.4 Graphic Layout 67

28、A8.5 Navigation 68 A8.6 Types of Graphics 69 A8.7 Displaying data (Colours/Graphical Objects/Text) . 71 Appendix 9 Determination of Number of Operator Screens . 76 Appendix 10 Use of “Windows” . 81 Appendix 11 Competency Assessment 84 Appendix 12 Simulators 86 A12.1 Low Fidelity versus High Fidelity

29、 Simulation . 86 A12.2 Benefits of Simulation 86 A12.3 Desired Features of a Simulation 87 Appendix 13 Example Screen Configurations 89 Appendix 14 Example Graphic Hierarchies 94 7. References 101 Bibliography 102 EEMUA Publication 201 - Process plant control desks utilising Human-Computer Interface

30、s EEMUA vii Figures Figure 1 A typical panel-based arrangement . 1 Figure 2 A typical first generation DCS system 2 Figure 3 A DCS system using graphics-based control 3 Figure 4 HCI, the sensory interface between operator and plant 4 Figure 5 HCI Roadmap 7 Figure 6 Human Factors of a Human-Computer

31、Interface . 8 Figure 7 The transition between the Optimum and Normal Operating envelopes 57 Figure 8 Operation state diagram for a continuous process 58 Figure 9 Continuous Process Screen Logical Diagram . 59 Figure 10 Conceptual model of the Batch Process plant 60 Figure 11 Batch Process Logical Sc

32、reen Hierarchy 61 Figure 12 Hybrid Process Logical Screen Diagram (1) . 62 Figure 13 Hybrid Process Logical Screen Diagram (2) . 63 Figure 14 Example of a standard graphics template 67 Figure 15 Example Symbols 73 Figure 16 Flowchart for determining the number of operator screens 78 Figure 17 Exampl

33、e of an oil refinery Control Desk Layout . 94 Figure 18 Example graphic covering two process units . 95 Figure 19 Display Hierarchy 96 Figure 20 Process Mimics Hierarchy 97 Figure 21 Display Formats - Relationships 98 Figure 22 Chemical Plant Graphic Hierarchy 99 Tables Table 1 Categories of operati

34、on . 4 Table 2 Different process types . 17 Table 3 Operator interface characteristics. 19 Table 4 Issues concerned with the use of multi-windows . 82EEMUA Publication 201 - Process plant control desks utilising Human-Computer Interfaces EEMUA viii EEMUA Publication 201 - Process plant control desks

35、 utilising Human-Computer Interfaces EEMUA ix Foreword Health and Safety Executive Human-Computer Interfaces (HCI) have become an area of increasing focus and importance to the UK chemical and allied industries in the major hazard sector, particularly with the advent of centralised control and the u

36、se of computer screens as key interfaces between processes and the operator. The first edition of this EEMUA guide has been widely used and referred to within the Chemical Industries (CI) sector of the Hazardous Installations Directorate (HID) and has proven to be very useful. The guide is equally r

37、elevant for: other parts of the major hazard sector e.g. offshore; non-major hazard process and other industries where HCI is used as a medium for process and plant control. While the term HCI may sound technical it describes something we are all very familiar with the display screens (VDUs) most of

38、 us increasingly use at home and in the workplace. Its that interface, as used in industrial and process applications, which can be so important in maintaining process and major hazard safety. Issues that may be just irritating to users at home or in the office, may have major safety implications as

39、 we have learnt from many disasters over the decades from the Texaco Milford Haven incident right up to the more recent Buncefield Oil Storage Depot explosion and fires. This guide is a very useful resource for industry, designers, manufacturers and suppliers in the major hazard sector. Inspectors a

40、nd specialists in HID will be looking for evidence that the standards and principles in the guide have been implemented appropriately both for new design, and for ongoing review and continuous improvement - of existing installations. The degree of rigour expected in applying the guide is of course p

41、roportionate to the hazards and risk under control but there are clear business and other benefits to good HCI design and use, as well as safety benefits. The renewed focus on HCI reflects well the current HID and HSE post-Texas City and Buncefield focus on process safety leadership, workforce invol

42、vement and wider human factor issues. Good leadership will help focus on HCI as one of a number of key areas that can influence - and optimise - human performance in the key area of a centralised control room and elsewhere. Good end-user involvement and user-centred design will provide good, workabl

43、e and valued interfaces, including the HCI. I commend this guide to you. Peter Baker Head of the Chemicals Industry Division, Hazardous Installations Directorate, Health and Safety Executive. EEMUA Publication 201 - Process plant control desks utilising Human-Computer Interfaces EEMUA x Abnormal Sit

44、uation Management Consortium In years past, operators of large industrial processes would perform, monitor and control activities from large panelboards. These contained scores of single loop controllers, indicators with trend charts and alarm annunciators for a limited number of key variables. Beca

45、use of the cost and limited size of the panelboards, project engineers spent considerable effort designing content and layout before implementation. Once built, operators learned the content, where to find things, and a feel for what was normal. At a glance, an operator could get a sense of the over

46、all process status from just about anywhere in the room. Navigation from one part of the unit to another was easy to learn - one simply walked from one location to another. Modern Distributed Control Systems (DCSs) have been justified based on improving control and optimisation, increasing throughpu

47、t, controlling at constraints, and expanding the board operators scope of control. Consciously or not, the demands on operator capability and performance have significantly changed. Indeed, the job of operators has transitioned from one of considerable reliance on knowledge of the plant layout and m

48、emorisation of a number of tasks to one more focused on process knowledge and cognitive skills. Humans are not particularly well suited for watching computer monitors hour after hour, waiting for something to happen which then rarely does. Plant managers and engineers did not fully understand the hu

49、man factors implications of the introduction of this new technology into the control room environment. Inadequately designed graphics for the operators in many cases leads to significantly diminished situational awareness and operator fatigue. The persistent paradox in the process industry is that as automation technology increases in complexity and sophistication, operators face progressively more complex decisions in managing the process. Moreover, the industrys ability to design effective operator interfaces to the process has