Operation Stations in a Distributed Control System

Part of DCS Training Course related to

1. Operationestations

2. Operailo

ns Work Center:

s essential functions:

Work stations e

Monitor p operations
atienti Jon t to process upsets and:
f hg corrective action when n

ms

OCCURING within the pro

hnel performing
on plant operating characte
tem is functioning properly

y

CO ‘trol

ulmagd

gineer Ahmed Aboulma

3. Operations Work Centers

Work stations typically in several’ video displays and
supplemented] by a variety of information devices, including:

« Alarm printers

« High speed repo! iters

« Video copiers

« User-assignable multipin trend recorders

« Annunciator lamps

+ Audible signals (messages)

4/7/2009 Prepared by Engineer Ahmed Aboulmagd

4. lenge Is t ide mechanisms. for monitorin
(sometime i of proc neters in an

spla

5. Process display
hierarchy

47/2009 PreparedbyEngineerA

6. Plant, area, unit &
sub-unit graphics

4/7/2009 I eparedibyjEng

7. Plant, area, Unit & sub-unit graphics

4/7/2009

FREE FORM GROUP/

8. Process display hierarchy navigation

r moving among these disp!

Cursor positions ng, usint
« Other Techn
Light pen
Mouse (a
Touch-se
= Joy: (

9. irchy navigation

a number of common

verydrom 1 imprope

J relati

on keyboards wit
he display on the video screen.

gineer Ahmed Abou!

10. Example of) a
variable function
keyboard

7417/2009 Prepared by|

11. Typical Group Display

4/7/2009

12. Example of control group display

G001 Raw Mill

FITETTTT

WC2010 WC2020 5 PDC2000 TC2100 TC2500 JC2700

LSFEED-1 LSFEED-2 E MILL DP OLTEMP BFOLTMP RECLOAD
TPH rpm Dee. k

SP- 180.0 200 80.0-

PV: 1812 208

812

MV- 482

GRO

1477/2008 Prepared by Engineer Ahmed Aboulmagd

13. Typical Detail Display

Real time trend Configuration number

4 poor
Controller 1 Slot 15 PID Gap Cont 060020000001 [o1yA00

er heiten 0.000

Groups

alarm
ci 5
A1
R1245
A1

\

0 |Diagnos
8 alarr
CINP1 +00316 GAIN 3.000 HI ALM 90.00

CINP2 +00314 RESET 2000 L2 LO ALM 20.00
CINP3 +00001 F RATE 0200 13 HI ALM 20.00
CINP4 +00001 F 8000 L4 DV LO ALM -20.00
CINPS 00001 20.00 LS OUT HI 100.0%
CINP6 00001 0.000 Ls OUT LO 0.0%

4 SP 1.000 L7 OUT RATE 100.0%

0.000
0.0% OVW INDEX 0.000
vom À 1000 EM DOWN 0.0%
t

Units of measure a Limits

Input pointers

4/7/2009 Prepared by Engineer Ahmed Aboulmagd

14. Typical Overview
Display,

7417/2009 Prepared by Engineer

15. List Display

4/7/2009

/

| [contar

[process

| Evatue

Process

Value

Value -0.031
Status

Pro

Value
Status

Process

input
Status 090000
Process input

Value
Status

Process

value

Range Hi
Range Lo

Range Hi
Range Lo

Range ra
Range Lo

Range Hi
Range Lo

Range ru
Range Lo

Range Hi
Range Lo

2800: Al
(0.00040 Alm,

5.000H All
0.000L0 Alm

2.0004 Alm
0,000L0 Alm

5000.44
100L0

5000. Hi Alm
150.0Lo Alm

1900,

4.500
0.090

5.000
5.000

4900

Gontiguration ward

Con 100000
Filter TC

Cont 1000

Filter TG

Cont 100012000012
Filter TC 5.000

ont 100016000010
Filter TC 1.000

Cont 000008000009
Filter TC 5.000

‘Cont 10000000000
Filter T

Filler TC

1 100000000001
ter TC 2.000

7

16. Typical Graphic Display

17. Example of graphic display

Raw Materiat Preparation Unit R1 12/09/2003 16:42

1477/2008 Prepared by Engineer Ahmed Aboulmagd

18. Typical trend Display

Beaty
Fearn

His
Hea

4/7/2009

1 REACTOR
eu
|

Prepared by Engineer Ahmed Aboulmagd

19. Typical trend) display

G1 12/09/2003 16:54

WERNE
ILSFEED-,

PY. 1812 208 141 2185 2212

7417/2009 Prepared by Engineer Ahmed Aboulmagd

20. Typical controller tuning display

WC2045 RAW MILL FEED CONTROL
SP=2160 LOOP= AUTO ALRMPR-HI
PV= 218.5
MV= 515

4/7/2009

21. Typical operator help message display

RAW GRINDING SECT:
OPERATOR HELP PAGE

12/09/2003 16:51:03 START DEDUSTING FAN
12/09/2003 16:51:54 OPEN INLETDAMPLER
12/09/2003 16:52:23 START MILL LUB.SYSTED
12/09/2003 16:52:45 MILL STARTED
12/09/2003 16:52:59 MILL FEED STARTED
12/09/2003 1 MILL ROLLERS DOWN
12/09/2003 16:53:31 MILL VIBRATION HIGH
12/09/2003 16:53:31 MILL ROLLER RAISED
12/09/2003 16:53:38 MILL FEED GATE CLOSED
12/09/2003 16:54:01 MILL FEED GATE OPEN
12/09/2003 16:54:01 MILL ROLLER DOWN
12/09/2003 16:54: MILL VENT FAN ON

1417/2009 Prepared by Engineer Ahmed Aboulmagd

22. Classification of alarms

Types of alarms

Depending on the priority

Zn

System Emergency High

4/7/2009 Prepared by Engineer Ahmed Aboulmagd

23. Process a
Indi
may be un

above or bel

sents an-abnormal condition in
g.0ffline, stopping of tt

red by Engineer Ahmed Aboul

24. d call for attention of

ne operator.

25. Operator Interfac

Prepared by Engineer Ahmed Aboulmagd

26. 4/7/2009

Initial Planning Sheet—Interface Design

Functionality of interface:
Variables to be indicated, recorded, adjusted, automatically alarmed co

Provide instructions, ancillary and historical information—Printed or computer-stored.

Extent of interactive graphics desired

Special tasks of interface

Will interface satisfy only functional needs, or will it be used also as a "show piece” for VIP
Visitations?

What are cost constraints? space limitations?

Are there special environmental considerations?—Installed indoors (air-conditioned space?)
outdoors, proximity to excessive noise, near moving machinery, vibration and shock, electrical
interference, corrosive or explosive vapors

Will design require guards, barriers or protective shields for components and user safety?

What degree of “ruggedness” is required?

Is there a requirement for information confidentiality?

Will interface be used constantly (three shifts) or be out of action parts of a 24-hour period or
weckends?. à a

Will operator instructions be simple or complex?

What will be the extent of operator training?..

Who will install equipment and maintain if2—User technicians, supplier, outside service
contractor?

How can installation and maintenance tasks be simplified?.

What are the choices in terms of overall physical configuration? ‘Console, workstation,
pedestal, desk?,

What are hardware options? Visual display, audi alarms, voice reception und wetivaion
Operator's physical contact with interface, switches, touch screens, etc.?

Are there any special procurement regulations, as for military installations?

Must the interface fit well into facility expansion plans?

. What are the physical and mental profiles of your present very successful operators? un

What have been common operator complaints in the past?
Will complexity justify preparing a life-size mockup for achieving an interface that combines
human factors with acstheties?

Functionality of operators—Complete job description, operator qualifications, physical size,
agility, alertness, other factors (from past experience),

Is nterace for a processor machine that could cause los of life or equipment if permitted to go
out of control? … E 3

27. Operator:
Interface
Geometry

7417/2009 Prepared by 4

ang wit splay screnn for
opium val traction

gn ino

Display height angle and
sarl ajustable o
Ira! preorenco

28. Glare from reflected ambient lighting

Lump filaments.
Direct

Glare n
lare

source (10) _ | To prevent reflections in
~ + eyeglasses, avoid light

sources within these angles

Displays

[y Diffuse reflections

from matte surface

4/7/2009 Prepared by Engineer Ahmed Aboulmagd

29. Alphanumeric Displays

30. Keyboards

Keyboard with standard QWERTY layout.

7417/2009 Prepared by Engineer Ahmed Aboulmagd

31. Keyboards

Dvorak simplified keyboard input

7417/2009 Prepared by Engineer Ahmed Aboulmagd

32. Typical operator keyboard

+ TDC 3000 @

217 2008) Prepared by Engineer Ahmed Aboulmagd

33. Typical operator Keyboard

34. iypical operator keyboard

+ Centum CS Y

G—ILSTSa Latas
1 IP 674 5741 674 574 5-4 54 5-4
CONDOM

Bo DE
a Ha
LM ÑO

a

v

1417/2009 Prepared by Engineer Ahmed /Aboulmagd

35. Basic DIN standard dimensions and
angular restrictions

4

= Middle key 19%
1

Keyboard angle limited
by key height restriction

Standard European desk height

4/7/2009 Prepared by Engineer Ahmed Aboulmagd

36. Panelboard
Concept

3
E
=
a
E
i
à
à
©

4/7/2009

37. 7
hb Tb
A}

5
23;
J

4/7/2009

38. DCS Operator Interface

39. Typical control loop:

Prepared by Engineer Ahmed Aboulmagd