Appendix C

International Society of Automation, (ISA),

Standard, Materials, Human Engineering,
and Control Room

ISA standards and other material data, human engineering, C.1 ISA STANDARDS
and control room concepts outline.
Presented below is a list of important and relevant ISA stan-
dards and technical papers.

TABLE C.1 List of Important ISA Standards

Publication Number
Main Ref. Sub Ref. Title
1-55617-531-0 Standards Library for Measurements and Controls (ISA)
12.00.01 – 01.01, 02.01 Electrical Apparatus for Use in Hazardous Locations

12.10 Area Classification in Hazardous (Classified) Dust Location

12.16.01 – 16.01, 22.01, 23.01, 25.01, 26.01 Electrical Apparatus for Use in Hazardous Locations (ISA)
18.1 Annunciator Sequence and Specifications (ISA)
20 Process, Measurements, Instruments, Primary Elements, Valves (ISA)
26 Dynamic Response Testing of Process Control Instrumentation
37.1 Electrical Transducer Nomenclature and Terminology (ISA)

37.3 Strain Gauge Pressure Transducers (ISA)

37.6 Potentiometric Pressure Transducers (ISA)
37.8 Specifications and Test of Strain Gauge Force Transducers (ISA)
37.10 Piezoelectric Pressure and Sound Pressure Transducers (ISA)
37.12 Potentiometric Displacement Transducer
5.1 Instrumentation Symbol and Identifications (ISA)

5.2 Binary Logic Diagram for Process Operations (ISA)

5.3 Graphic Symbol for Distributed controls/Shared Display System (ISA)
5.4 Instrumentation Loop Diagrams (ISA)
Continued

1067
1068 Appendix C

TABLE C.1 List of Important ISA Standards—cont’d

Publication Number
Main Ref. Sub Ref. Title
5.5 Graphic Symbols for Process Display (ISA)
50.02.2 –.–. 2,3,4,5,6 Fieldbus Standard for Use in Industrial Control Systems (ISA)
TR 50.02-9
51.1 Process Instrumentation Terminology
71.01 –. 01,02,03,04 Environmental Conditions Process Measurements, Control Systems
(ISA)
75.01.01 Flow Equations for Sizing (CVs) (ISA)
75.02 CV Capacity Test Procedure (ISA)
75.03 Integral Flanged Globe Style CV bodies (ISA)

75.04 Dimension for Flangeless CV (ISA)

75.05 CV Terminology (ISA)
75.11 Inherent Flow Characteristics, Rangeability of CV (ISA)
75.12 Socket Weld, Screw End Globe Style CV (ISA)
75.13 Method of Evaluating Performance of Positioner (ISA)
75.14 –.14,15 Dimensions of Butt Weld End Globe Style CV (ISA)

75.16 Dimensions of Flanged Globe Style CV (ISA)

75.17 CV Aerodynamic Noise Production
75.19 Hydrostatic Testing of CV
75.22 Dimension of Flanged Globe Style Angle CV (ISA)
77.13.01 FFPP Steam Turbine Bypass
77.20 FFPP Simulator Functional requirements (ISA)

77.41 FFPP Boiler Combustion controls (ISA)

77.42.01 FFPP Feedwater Control Systems (ISA)
77.43 FFPP Unit/Plant Development (ISA)
77.44 FFPP Steam Temperature Control Systems (ISA)
77.70 FFPP Instrument Piping Installations (ISA)
82.02.01, 82.03 Safety Standard for Electrical and Electronic Equipment (ISA)

82.02.02, 82.02.04 Safety Standard for Electrical Equipment (ISA)

92.02.01-1, Carbon Monoxide Detection Instruments (ISA)
92.02.02

RA8425 Standards Library for Automation and Control

REWIC01 Programmable Logic Controllers in Safety-Related System
REWIC02 Achieving Safety in Distributed Systems (ISA)
RP2.1 Manometer Tables (ISA)
RP42.1 Nomenclature for Instruments Tube Fittings (ISA)
RP60.3 Human Engineering for CC (ISA)

RP60.4 Documentation for CC

RP60.6 Name Plate, Labels, Tags for CC
 Appendix C 1069

TABLE C.1 List of Important ISA Standards—cont’d

Publication Number
Main Ref. Sub Ref. Title
RP60.8 Electrical Guide for CC
RP60.9 Pipe Guide for CC
TR77.60.04 FFPP Human Machine interface

CC, control centers, CV, control valve, FFP, fossil fuel power plant.

C.2 MATERIAL COMPOSITIONS

Presented below is a list of important and relevant materials
with the associated composition normally used in power
plants.

C.2.1 Carbon and Ceramics

TABLE C.2 Carbon and Ceramics Composition Details

Material Type Materials Description
Carbon Karbate (carbon) Impervious carbon
Karbate (graphite) Impervious graphite

Ceramics Pfaudler glass lining Glass-lined metallic equipment (steel)

Plate glass lining Polished plate glass, flat or bent
Pyrex Glass type

C.2.2 Plastics and Rubber

TABLE C.3 Plastics and Rubber Composition Details

Material Type Materials Description
Plastic Koroseal Plasticized polyvinyl chloride
Polythene Polyethylene

Teflon Polymerized tetrafluoroethylene

Tygon Synthetic compound
Rubber Ace hard rubber Vulcanized rubber
Butyl Solid copolymer of isobutylene and isoprene
Neoprene Polymer of chloroprene
Nitrile Rubber or NBR Synthetic rubber copolymer of acrylonitrile and butadiene
1070 Appendix C

C.2.3 Metals broad spectrum. For actual composition, relevant standards

such as ASTM and DIN should be referenced.
All elements are indicated in their chemical formula and the
amount in percentage if not in traces. This composition is a

TABLE C.4 Commonly Used Metal Alloy Composition Details

Brass Cu 60–65, Zn 35–40, Pb 0.5–3
Brass red Cu 85, Zn 15
Bronze (comm) Cu 90, Zn 10
Bronze phosphor Cu 88, Zn 4, Sn 4, Pb 4

Bronze phosphor 10% Cu 89.5–90, Sn, P 10–10.5

Hastelloy A Ni 17–21, Mo 17–21, Fe
Hastelloy B Ni 24–32, Mo 3–7, Fe 0.02–0.12, C
Hastelloy C Ni 14–19, Mo 4–8, Fe 0.04–0.15, C 12–16, Cr 3–5.5, W
Hastelloy D Ni 8–11, Si 2–5, Cu 1, Al
Monel Ni 67,Cu 30, Fe 0.15, C

Nickel Ni 99.4, Mn 0.2, Cu 0.15, Fe 0.05, Si

Nickel-silver A/B A: Cu 65, Ni 18, Zn 17
B: Cu 55, Ni 18, Zn 27

Platinum Pt 99.99
Silver Ag 99.9
Stainless steel (SS) 301 Fe 16–18, Cr 6–8, Ni 0.08–0.15, C
SS302 Fe 17–19, Cr 8–10, Ni 0.08–0.15, C
SS303 Fe 17–19, Cr 8–10, Ni 0.15 (max), C 0.07 (min), P, S, Se 0.6
SS304 Fe1 8–20, Cr 8–11, Ni 0.08 (max), C 2 (max), Mn

SS310 Fe 24–26, Cr 19–22, Ni 0.25 (max), C

SS316 Fe 16–18, Cr 10–14, Ni 0.1 (max), C 1.75–2.75, Mo
SS317 Fe 16–18, Cr 10–14, Ni 0.1 (max), C 1.75–2.75, Mo
SS321 Fe 17–19, Cr 8–11, Ni, Ti 5  C
SS347 Fe 17–19, Cr 9–12, Ni, Cb, 10  C (min)
SS403 Fe 11.5–13, Cr 0.15 (max), C

SS410 Fe 11.5–13.5, Cr 0.15 (max), C

SS416 Fe 12–14,Cr 0.15 (max), C 0.07 (min), P, S, Se 0.6 (max), Mo
SS430 Fe 14–18, Cr 0.12 (max), C
SS446 Fe 23–27, Cr 0.35 (max), C 0.25 (max), N
Steel Normal carbon steel C < 0.2, Mn 1.5 (max), Si 0.1%–0.2%, Cr 0.4, S 0.06–0.3, P 0.04
Tantalum >99.9 Ta

Worthite Fe 20, Cr 24, Ni 0.07 (max), C 3.25, Si, 3, Mo 1.75, Cu 0.5, Mn

 Appendix C 1071

C.2.4 Service Temperature Limit of a C.3 ERGONOMIC CONTROL ROOM

Number of Commonly Used Materials DESIGN CONCEPTS
Human engineering based on ISA RP 60.3 and ergonomic
TABLE C.5 Temperature Limits for Commonly Used design of control rooms based on ISO 11064 (various
Materials parts) are discussed. In Fig. C.1, reachability of humans
along with control room design basics are depicted to
ASTM Description Temperature
get an idea about control room design. Today’s superior
Designation/ Range (°C)
ergonomic design makes it possible to have several
Trade Name
large screens at the back (behind the workstation console),
EPDM Ethylene propylene 40 to 135 screens in the front, live video, and process control
terpolymer graphics, etc. For a better control room environment,
NBR Nitrile 54 to 82 remote graphics make the control room computer free.
NR Natural rubber 29 to 93
In modern control rooms, operators control local temper-
ature, lighting, etc. Also, large screen units and work-
PTFE Polytetrafluoroethylene 73 to 204 station consoles are motorized so that height as well as
Polytetrafluoroethylene 73 to 232
(glass/carbon filled)
distance between them can be adjusted for better viewing.
Modern control room concepts (based on ABB EOW-
Flexible 185 to 540 Technical Specification) are shown in Fig. C.2. In some
graphite,
Grafoil
control systems, even dedicated iPads are used as control
devices (e.g., 800  of ABB).

C.2.5 Designation of Commonly Used High C.3.1 Human Body Dimensional Details
Nickel Alloys The data given below are based on ISA RP60.3. Only
major relevant data are presented, and are based on normal
humans (male). Unless otherwise stated, data are in
TABLE C.6 Casting Designation of Commonly Used meters.
Alloys
Casting Wrought Generic
Designation Trade Name Designation
TABLE C.7 Human Body Dimensional Details (Human
CF3 304L Engineering)
CF8 304 Human Dimensional 5th 95th
CF3M 316L Position Element Percentile Percentile

CF8M 316 Standing Vertical reach 1.9 2.2

on the (hand up)
CG8M 317 floor
Eye to floor 1.5 1.7
CW2M New Hastelloy C Alloy C276
Side arm reach 0.7 0.8
CXW2M Hastelloy C22 Alloy C22 from center of
CW6MC Inconel 625 Alloy 625 body on either
side of body.
CY40 Inconel 600 Alloy 600
Forward arm 0.7 0.8
CZ100 Nickel 200 Alloy 200 reach (in front)
LCB LCB Chest 0.87 1.1
circumference
LCC LCC
Elbow to floor 1.0 1.2
N7M Hastelloy B2 Alloy B2
(In body) Head height – 0.255
WCB WCB
Chin to eye 0.125
WCC WCC
Arm swing (aft) 40°
Continued
1072 Appendix C

C.3.2 Ergonomic Considerations for Control

TABLE C.7 Human Body Dimensional Details (Human
Engineering)—cont’d
Room Concepts
In the past, basic human factors were a functional grouping
Human Dimensional 5th 95th
of instruments for operational facilities. However, in the
Position Element Percentile Percentile
modern control room there are so many ergonomic factors
Sitting on Sitting height to 1.3 1.4 to be considered that the design is foolproof and helpful to
a chair floor
placed
the operators. The human factor, the machine (hardware
on the Eye distance from 1.2 1.3 and software), the work environment, and the control (oper-
floor ation and management) need to be in harmony and inte-
floor
(standard chair)
grated during all phases of the design process. In line
Standard chair 0.45 0.45 with ISO 11064, the basic steps for such a design are
height from floor depicted in Fig. C.1C. In the following clause, other factors
Vertical reach 1.1 1.3 are discussed.
Top of head to 0.84 0.95
seat (sitting level)
Eye level to seat 0.7 0.83 C.3.2.1 Layout
level l The control room layout must take into account both 5th
Thigh clearance 0.12 .162 and 95th percentile data.
(above seat) l Layout should be done after task analysis and both link
Forearm length 0.34 0.405
and hierarchical task analysis.
l Emergency exit must be considered for 99th
Seat length 0.37 0.54 percentile.

(A)

(D) (E)

(B) (C)
FIG. C.1 Control room concept.

(A)
FIG. C.2 Modern control room concepts.
l Adequate space and suitable use of space needs to be
designed, while taking into consideration traffic flow,
etc. Flow from general circulation areas should be
discouraged.
l Line of sight and communication means are important
factors in the layout of the control room.
l Allocation of responsibility and the requirements of
supervision during high as well as low staffing periods
is essential.
l While creating the layout the designer must consider a
300–700 mm distance between intimate zones (other’s).
C.3.2.2 Temperature and Air Flow
Temperature varies little from place to place, but a com-
fortable range is 24  2°C (some places may demand lower
than this, for example, 18–20°C), and air flow should be
0.11–0.15 m/s with suitable makeup. The current trend is
for the operator to have his own comfort control.
C.3.2.3 Lighting
Suitable lighting is extremely important to avoid maladies
like headaches and eye pain. The displays should be glare
free, with no reflecting surfaces, including veiling
reflection on the video display units. All illumination
should be flicker free. Normally 500–800 lux is recom-
mended. The current trend is to use a high-frequency illu-
mination system as shown in Fig. C.2.
Appendix C 1073
(B)
C.3.2.4 Sound Level and Alarm
Sound level in the control room should never be > 85 dB.
Noise level should never cause a hindrance to the operators’
attention to warnings and decision making. It has been
found that blinking of lights and pulsating sound draws
attention. During emergencies this will be a hindrance,
making it difficult for the operator to take action. In modern
plants, hundreds of alarms may occur when a unit trips, but
many of them may be repetitive, so there should be some
grouping and group acknowledgment of the alarms if pos-
sible. Alarm management is very important for this reason
in modern units.
C.3.2.5 HCI Features and Alarm Management
See Chapter 7, Clause 5.
C.3.2.6 Coding
Coding by color, symbol, sound, shape, inverse video, etc.,
is quite common. However, these codes should follow inter-
national standard and should be consistent throughout
the plant.
C.3.2.7 Text and Labels
These must also follow international standards and be con-
sistent throughout the plant. (For further reference, see ISA
RP 60.4 & 60.6.)
1074 Appendix C
BIBLIOGRAPHY
[1] Standard Design Criteria/Guideline for Main Plant Package (2  500
MW TPP):Central Electricity Authority: New Delhi.
[2] B.G. Liptak, Process control and optimization, in: B.G. Liptak (Ed.),
Composition of Metallic and Other Materials, vol. II, CRS Press/
Taylor & Francis, 2006.
[3] B.G. Liptak, Process control and optimization. In: B.G. Liptak (Ed.),
Human Engineering, vol. II, CRS Press/Taylor & Francis.
[4] EOW-x2 A superior complete workstation for System 800xA: ABB
Limited: Technical Specification.
[5] Ergonomics—Control Room Design: AngloAmerical AA Standard.
[6] T. Naito, N. Takano, E. Inamura, A. Hadji, Control Room Design
for Efficient Plant Operation, (2011). Yokogawa Technical Report.
[7] Planning and Design of a Control Room: The Winsted Corporation
USA: Tech. Write Up.
[8] Control Room Design, http://www.hse.gov.uk/comah/sragtech/
techmeascontrol.htm.
[9] System 800xA Extended Operator Workplace EOW-x: ABB Limited.