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Designing an Ethylene Plant Control Room and Operator User Interface Using Best Practices J. Errington NOVA Chemicals Inc. I. Nimmo User Centered Design.

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Presentation on theme: "Designing an Ethylene Plant Control Room and Operator User Interface Using Best Practices J. Errington NOVA Chemicals Inc. I. Nimmo User Centered Design."— Presentation transcript:

1 Designing an Ethylene Plant Control Room and Operator User Interface Using Best Practices J. Errington NOVA Chemicals Inc. I. Nimmo User Centered Design Services Prepared for presentation at 2001 Annual Meeting, Houston, Texas. Copyright  Jamie Errington, NOVA Chemicals Corp, Joffre, AB and Ian Nimmo, User Centered Design Services 78F

2 2 01/03/20 Copyright Acknowledgements u The authors wish to acknowledge the support of: –Tim DeMaere - NOVA Chemicals Inc. –Peter Bullemer - Honeywell Technology Center

3 3 01/03/20 Copyright Objective & Outline u Objective: –Outline the design process and results of NOVA Chemicals’ E3 Manufacturing Building and User Interface u Presentation Outline –Background –Overview of ASM (Abnormal Situation Management) and Best Practices –E3 Manufacturing Center Building Location Building Design –E3 User Interface

4 4 01/03/20 Copyright Background u Ethylene 3 –2.8 Blbs/y - ethane cracker –project kick-off 1997 –mid-2000 startup –located in Joffre Alberta, Canada –joint venture between NOVA Chemicals and Union Carbide u Designing for Abnormal Situation Management –AIChE paper presented in 1998 at New Orleans –Described how NOVA Chemicals was applying ASM Best Practices information to the design of new facilities

5 5 01/03/20 Copyright Joffre Opportunity in 1998 u Concurrently Building New Facilities –Utilities Plant Expansion –Ethylene 3 –Polyethylene 2 u Training Simulators –E3 –PE2 u Exposure to ASM - AEGIS Prototype u Management Support of ASM program

6 6 01/03/20 Copyright ASM - Abnormal Situation Management u Consortium of companies and university affiliates: –NOVA Chemicals, Exxon/Mobil, BP/Amoco, Shell, Chevron, Texaco, Celanese, Union Carbide, Phillips –Honeywell (IAC, HTC) –BAW –Purdue, Ohio State, University of Toronto u NOVA Chemicals joined in 1994

7 7 01/03/20 Copyright Goals of the ASM Consortium u Reduce preventable process upsets by 90% u Understand the problem –Site Surveys u Develop better methods for aiding operators during process disruptions –AEGIS prototype u Improve other Supporting Systems –Collateral Studies –Other technology Deliverables Not by Technology alone!

8 8 01/03/20 Copyright ASM Best Practices u Compiled from extensive site reviews across a wide spectrum including: –Training –Procedures –Tracking and Reporting –Communication Systems –Work Context and Environment

9 9 01/03/20 Copyright Control Centre Location u Goal –“to build a control center that will enhance the human performance in and around the control room” u Location Design Process –literature survey –multi-discipline team examined alternative locations –evaluated on cost, impact on people, safety implications, business issues u Review Solutions –remote - centralized control building - multiple plants –centralized control building within battery limits –individualized distributed control buildings u Selection –individual distributed control buildings u Driving forces –communications within unit –higher personnel safety

10 10 01/03/20 Copyright Manufacturing Building u Goal –to enhance how the manufacturing team (Operations, Maintenance and Technical) control system works together in and around the control system u Building Design Process –Created design vision for the building –Interviewed primary users at adjacent Joffre units for needs and requirements –Iterative process to refine key elements and share vision u Key components –control room was the center of focus –communication patterns in the control room and the building –determined adjacency matrix prioritized the layout and size of rooms task segregation (permitting, meetings, etc.) traffic flow patterns –control console layout

11 11 01/03/20 Copyright E3 Control Room

12 12 01/03/20 Copyright User Interface u The goal of the User Interface Design is to improve operator access to information thereby improving plant performance. u Principal design aspects which have been considered in the design were: –Navigation –Visual Coding –Alarm Information live alarms AOA design information –Control Information cascades critical / redundant instrumentation –Trend Information –On-line Documentation

13 13 01/03/20 Copyright User Interface

14 14 01/03/20 Copyright User Interface u Status View –Level 1 - Area Overview –Alarm Summary u Operations View –Level 2 - Unit Summary –Level 3 - Sub-unit –Level 4 - Group Displays

15 15 01/03/20 Copyright Status View

16 16 01/03/20 Copyright Operations View

17 17 01/03/20 Copyright Task- and System-based model integration u Research Project –University of Toronto / Honeywell/ NOVA and ASM Consortium u Task Modelling –focus on the user’s tasks, plans and goals u System Modelling –functional structure of the plant or system –captures the physical and chemical principles

18 18 01/03/20 Copyright Conclusion u Manufacturing building design has been successful u User interface design is a bold step that will get even better with new developments –online information, –new modelling approaches, and –faster computers


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