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4.3 Control Center Upgrading

*
B. J. GEDDES (2002)

Cost: Workstation costs range from $10,000 to $30,000 depending on the number of flat
panel displays, video display units, computers, and input devices. Where new screens
replace analog instruments in a conventional panel, cost is typically $5,000 per screen.
The above costs do not include hardware/software integration.

Partial List of Suppliers: ABB Instrumentation (www.abb.com/us/instrumentation)

Barco Projection Systems (www.barco.com)
Clarity Visual Systems (www.clarityvisual.com)
Emerson Process Management (www.easydeltav.com)
Framatome ANP (www.framatome.com)
General Electric (www.ge.com)
Invensys Process Systems (www.invensysips.com)
Raytheon ELCON Digital Display Group (www.ifp-beisch.com)
Rockwell Automation (www.rockwellautomation.com)
Siemens Energy & Automation Inc. (www.sea.siemens.com/ia)
Westinghouse Electric Co. (www.westinghouse.com)

As process plants age, owners must consider a variety of asset
life cycle management issues, including instrument and con-
trol (I&C) system obsolescence. Plants constructed prior to
the early 1970s were predominantly supplied with analog
instruments and controls, either electronic or pneumatic.
It is likely that the vendors who supplied these original
analog systems no longer provide parts or services to keep
them running. As computer chips and information systems
became available through the advent of the information age,
instrument and control system vendors found innovative ways
to apply this digital technology across their product lines.
Systems and components are now smaller, more reliable, and
fault tolerant, and they can perform multiple functions that
were previously spread across multiple, discrete components.
Today, process engineers are presented with a variety of
digital components and systems ranging from transmitters,
switches, relays, breakers, controllers, recorders, indicators,
video displays, distributed control systems, fieldbuses, and
networks to connect them all together. The control system
vendor may supply any or all of these new components and
systems as replacements for the original equipment.
Digital information and control technology offers a variety
of entry points in the analog process plant. The entire plant can
be upgraded at once in one outage, or the owner and designer
can choose to upgrade one system or component at a time. The
technology is flexible enough to consider any upgrade path,
which almost always has an effect on the control room.
The designer has two basic choices:
1. Building a New Control Room—If the plant is still
operating, but has excessive cost or obsolescence prob-
lems in the I&C system or in the control room, then
a new control center (building) may be economically
justified. A new control center will be built as close
as possible to the old control room or control center,
so operations and maintenance tasks that require prox-
imity to plant equipment can be maintained. This
option also has the advantage of allowing construction
to proceed while the plant is operating.
2. Upgrading the Control Room as Required (Phased
Approach)—If the plant can still meet its business
goals safely and effectively, and obsolescence is not
yet a significant safety, reliability, or cost issue, then
the designer can select an upgrade path for the plant
on a system-by-system basis that accounts for time-
to-obsolescence. System upgrades can be performed
while the plant is in production, or during routine
maintenance outages. Over time, the control room will
have the same basic layout as that supplied during
original construction, but the panels and furniture will
be configured with modern technology where it is
needed. Original indications and controls that are not
obsolete and can still be easily maintained may
remain as-is, but they will be reintegrated in a hybrid

*
This section been reprinted with minor additions and changes, from Volume 3 of the Instrument Engineers’ Handbook, which is titled: “Process Software
and Digital Networks.”

618
© 2006 by Béla Lipták
1081_C004.03.fm Page 619 Monday, August 22, 2005 2:44 PM
analog/digital design with modern human machine
interfaces.
Designers must consider the impact on the control room
when applying new technology in any part of the plant. Even
a seemingly innocuous plant change can impact the control
room. For example, a digital, fieldbus-compatible process
transmitter may offer a local upgrade path for a given plant
system. But this transmitter now supplies much more infor-
mation than the original 4–20 mA DC transmitter, and it
should be applied in the context of a total plant architecture
that will impact the control room as it evolves.
It is critical to see beyond the immediate needs of the
plant. Plant owners will naturally tend to apply funding and
resources to the I&C systems that cause the most trouble and
stop until the next acute need arises. Acute system problems
usually have a significant impact on plant safety or produc-
tion, and the designer owes a more proactive and compre-
hensive approach to the owners.
BASELINE EVALUATION
The goal of the baseline evaluation is to ensure the upgraded
control room still functions well within the original plant.
The functional allocations between humans and machines
should be well understood and documented. Operations and
maintenance tasks should be understood and documented,
Internet
Enterprise
Operations
Maintenance/
Engineering
Control/
Computing
Signal
I/O
Conditioners
Plant sensors and control elements
FIG. 4.3a
Analog I&C architecture.
© 2006 by Béla Lipták
4.3 Control Center Upgrading 619
and information zones should be mapped and correlated with
these tasks. More importantly, the baseline will also ensure
that the control room operating staff’s sense of how the plant
is designed and operated will be maintained with the modified
or new control room.
The designer must first understand how and why the orig-
inal control room is designed the way it is, then understand
the basic operating philosophy of the control room staff. The
operating philosophy can be defined as the set of rules and
procedures matched with the set of roles and responsibilities
of operating staff resources that are applied during all modes
of operation, including normal, abnormal, and emergency
operations. Operating staff (control room supervisors, control
room operators, and system operators) roles and responsibil-
ities in an existing plant are based on the functional allocations
between humans and machines, which then determine the
tasks assigned to humans in all phases of plant operations.
The baseline evaluation should begin with an evaluation
of the basic design of the existing plant information and
control systems by reviewing loop diagrams, schematics, wir-
ing diagrams, and panel layout/cutout drawings. Figure 4.3a
represents an architectural perspective for the analog I&C
systems and components in a typical older process plant.
Each set of systems and components can be categorized by
its basic function.
The cloud at the bottom of Figure 4.3a comprises the
basic sensors such as pressure, temperature, flow, level, and
5983
RTD
Xmitters
1081_C004.03.fm Page 620 Monday, August 22, 2005 2:44 PM
620 Control Room Equipment
position switches, various measurement elements, and analog
process transmitters. It also represents final control elements
such as motor control centers, motor-operated valves, air-
operated valves, dampers, and machines. This population of
sensors and control elements usually numbers in the thou-
sands for large process plants.
The input/output (I/O) layer just above the cloud at the
bottom of Figure 4.3a represents the basic I/O systems that
may be used by what few digital platforms are employed,
such as a mainframe plant process computer.
The mainframe computer, in the control/computing layer,
typically runs a real-time database program for those plant
variables that need to be stored and retrieved in group dis-
plays or reports, or used as input data for complex perfor-
mance calculations. The number of data points assigned to
the plant process computer may number in the thousands,
but its role is limited to information-only applications.
The maintenance layer represents any interfaces made
available to maintenance and engineering. The only inter-
faces that are available to maintenance and engineering in
the analog plant are confined to the one or two computers
that may be used in specialized applications.
The operations layer represents the devices used by the
plant operator, and it can be seen that the majority of the devices
in Figure 4.3a are in this layer. These devices include trend
recorders, digital indicators, vertical and horizontal meters, a
variety of hand switches, single-loop controllers, lamps, and
annunciator light boxes. By inspection, most of the analog plant
sensors in Figure 4.3a terminate directly on these devices used
by the operators. Any maintenance required on these analog
loops will usually take the affected devices out of service and
result in a negative impact on the operation of the plant due to
disruptions and loss of information and control.
Finally, the enterprise layer illustrates the basic plant or
company enterprise where information technology (IT) sys-
tems are deployed. Operators may have a company PC at
their disposal in the control room for retrieving enterprise
information such as drawings or accounting data, or sending
and receiving e-mails. This PC is only connected to the office
local-area network (LAN) and is not used directly to operate
or maintain the plant.
Changing any component in the lower layers of
Figure 4.3a can impact the operations layer, and vice versa.
For example, the plant may need to upgrade a set of plant
sensors due to obsolescence. The signals from the old sen-
sors were processed by the mainframe computer. The new
sensors require a new software code to properly acquire and
convert their signals to the engineering units required by
the operator. The new software cannot run on the old main-
frame computer, so a new computing platform is needed in
the form of a server, which comes with a client software
package for use on a PC or workstation in the control room.
The server can also be integrated with a DCS (distributed
control system). Now we have a complete system upgrade
that affects every functional layer in Figure 4.3a, with sig-
nificant control room impact.
© 2006 by Béla Lipták
FIG. 4.3b
Analog control room.
ORIGINAL DESIGN PERSPECTIVE
Figure 4.3b shows an older control room, typical of power
plants and other process plants designed and built between
the late 1960s and the early 1980s. The majority of the
indications and controls are from original construction and
are almost all analog instruments. Some plant systems have
been upgraded since original construction, but only on an as-
needed, system-specific basis. No serious consideration has
been given yet to a total control room modernization effort.
The operator interfaces are typically located on “stand-
up” control panels and are used by control room operators
during normal and emergency operations. Desks are provided
for senior control room operators and control room supervi-
sors, with telephone and radio equipment and terminals con-
nected to a mainframe plant process computer. The panels
are laid out by major plant functions such as electrical sys-
tems, cooling water systems, major machine controls (e.g.,
turbine/generators or compressors), reactor controls, and
emergency systems.
On each panel, indications and controls are grouped by
specific plant systems or functions. For example, Figure 4.3c
shows a feedwater control system panel from the same control
room shown in Figure 4.3b. Annunciator windows are on the
top plane of the panel. Feedwater heater level indications are
grouped on the left-hand side of the vertical plane. Steam
generator temperature and level indications are grouped on
the right-hand side. Across the bottom planes are indications
and controls associated with the control elements for feed
pump turbines, condensate pumps, and various valve position
indications and controllers. Groups of instruments and con-
trols are bordered or separated by a thick black demarcation
line called “zone banding.”
Each group of instruments and controls can be associated
with a set of operator tasks for each mode of plant operation
(start-up, normal, shutdown, and emergency operations).
1081_C004.03.fm Page 621 Monday, August 22, 2005 2:44 PM
FIG. 4.3c
Analog control panel.
Written procedures describe operator actions required for
responses to various alarms or during various controlled tran-
sients. Operators are trained in a full-scale simulator for
various operating modes and equipment failure scenarios, and
they are trained to perform periodic visual scans, or surveil-
lances, of each group of indications and controls either close
up or from a “total control room” perspective. The baseline
evaluation should capture all of these operator tasks and their
associations with each group of indications and controls.
INFORMATION ZONES AND TASK ANALYSIS
Perhaps the most significant design aspect of an older, analog
control room is that all plant indications and controls are in
discrete locations on the panels. Most plant variables are only
readable from one instrument in a “fixed position” on a panel,
and plant system variables are grouped in “information
zones” where operators are trained to look for patterns in the
indications to detect, diagnose, and maintain or mitigate var-
ious plant conditions. The information zone human–machine
interface (HMI) design concept is a very strong paradigm for
operators, and should not be significantly modified or cor-
rupted unless a new control room is built, complete with a
new task analysis, operating procedures, and operator retrain-
ing and qualification program. In the phased approach, infor-
mation zones are kept intact as each zone is upgraded over
time.
Each information zone is associated with a set of operator
tasks, which should be studied and evaluated using simulators
or mockups. Tasks will vary with modes of plant operation.
Most operator tasks in a continuous process plant will be
associated with surveillance of the process systems. During
routine surveillances, an operator will visually scan the con-
trol panels looking for patterns in the indications and alarms
© 2006 by Béla Lipták
4.3 Control Center Upgrading 621
that indicate plant systems are operating within specifica-
tions. Some manual manipulations of multichannel meters or
displays may be required.
In an upset mode, such as a sensor or equipment failure,
or a trip of a major plant machine or the plant itself, an
operator’s task loading will shift dramatically, and will be
focused on key plant variables and controls. Alarms will be
prioritized by the operator per procedures and training plans,
and the event will be diagnosed and mitigated through the
cognitive strengths of the human operator. The HMI will be
designed to accommodate this shift in task loading with an
emphasis on decision making.
Once the task evaluation is captured, operating experi-
ence should be evaluated. Operating logs and event reports
should be reviewed for positive or negative trends in plant or
human performance. Operators should be interviewed to see
if there are any HMI issues that need to be improved or
corrected. Are there any recurring situations where operators
are tasked with too many simultaneous inputs requiring con-
current actions? How do operators prioritize their actions
under these scenarios? Are there any operator tasks where
there is a deficiency in available information, such as reso-
lution, timeliness, or readability? Are there any indications
and controls that are too difficult to read or understand, or are
simply not available under certain conditions where they are
required for an operator task?
If an operating experience review indicates deficiencies,
event scenario walkthroughs should be conducted in a full-
scale simulator if one is available. If a full-scale simulator is
not available, a full-scale mockup of the control room should
be built. At first, a mockup of the old control room might
seem like a waste of time, but it can support an engineering
analysis of the strengths and weaknesses of the old control
room without disturbing plant operations, and it can support
experimentation and evaluation of new design concepts as
they are integrated in the original control room if the phased
approach is used.
Figure 4.3d shows a 1/8 scale mockup of the same control
system panel shown in Figure 4.3c. It was made by reviewing
photographs and layout and cutout drawings of the panel, then
making a scale template of each plane on a personal computer
using Visio, a commercial graphics software package.
Objects for each type of control panel device (recorders, indi-
cators, controllers, etc.) were made and stored in a Visio
stencil, then applied to the scale template using a “drag and
drop” technique. Each panel was printed on a color printer or
plotter, spray-glued to a piece of cardboard, then cut out and
assembled using a hot glue gun. The total cost of the software
and materials for this mockup was less than $100.
The engineering and technician time invested in building
the object library, or stencil, and preparing this first panel
was over 100 hours, but subsequent panels take less time
and the library is now available for finishing a mockup of
the entire control room. This mockup was prepared at full
scale in the computer, then printed at 1/8 scale for this
version. The same Visio files can be printed at full scale on
1081_C004.03.fm Page 622 Monday, August 22, 2005 2:44 PM
622 Control Room Equipment
FIG. 4.3d
Panel mockup.
an engineering plotter, and applied to a full-scale plywood
mockup, which is useful for walkthroughs with operators.
Finally, the baseline evaluation should examine all of the
operating and maintenance costs associated with the original
I&C systems in the plant. If an older, analog plant is expected
to have a long operating life, many if not all of the I&C
systems will need to be replaced. These replacement activities
will be necessary to maintain continued plant operation, to
take advantage of current technology, to improve plant avail-
ability, and to facilitate further reductions in operating and
maintenance costs.
The most significant economic driver is usually obsoles-
cence, which can be changed from a liability to an asset in
considering control room upgrades. When obsolescence is con-
sidered in aggregate, a strong economic case for an integrated,
modern control room can be made. A system should be con-
sidered obsolete when any of the following criteria are met.
1. The system will not meet the operational demands
required of it during all phases of plant operation, includ-
ing normal, abnormal, offline, online, and emergency
situations.
2. The parts manufacturer has formally announced that
it will no longer directly support the system or com-
ponent, or will require a significant increase in com-
ponent cost to continue support.
3. The system or component will not interface with new
components that are required in other systems. It is
virtually assured that if the operational life of a process
plant is extended, all system components will require
some form of major component replacement.
4. The system or component cannot support plant oper-
ations that are desired by the business plans.
© 2006 by Béla Lipták
Once the baseline evaluation is completed, the plant
owner and the designer will have an accurate assessment of
the functional, performance, and economic state of the plant
I&C systems and, in particular, the control room. Goals and
objectives can be clearly described, and upgrade options can
be estimated and undergo a total cost–benefit analysis.
BUILDING A NEW CONTROL ROOM
Building a new control room all at once allows the full
potential of modern I&C systems to be immediately realized
in an older process plant. A new control room in this context
means the complete retirement and replacement of the orig-
inal analog panels, I&C systems and HMI components with
new digital systems, using a DCS or PLC (programmable
logic controller) platform. The replacement systems may be
installed in the original room, or may be installed in a new
building or otherwise spare plant location.
If the plant can no longer meet its business goals safely
and effectively because of control system degradation and
obsolescence, it probably needs a major overhaul, and an
entirely new control room may be in order. If a plant is being
overhauled for a major capital upgrade (new reactors, boilers,
compressors, turbine generators, or other major machinery),
it will probably include a new process or machine control
system. The designer can engineer a new control house and
demolish or retire the old one in place, or gut and rebuild the
existing control room. The new control room should be imple-
mented with a workstation/console arrangement designed to
maximize safety, quality, reliability, and productivity with a
heavy emphasis on human engineering.
The decision to build an entirely new control room all at
once has profound implications for the entire process plant.
The designer can demolish the old control room by removing
all components and structures, including panels and furniture,
leaving floor and ceiling slabs and four bare walls, with field
cables pulled back or left coiled near their penetrations.
Using this approach, an analog control room is replaced
with a fundamentally new “glass control room,” or one that
consists of video display units (VDU) located on operator
workstations or consoles and can also include one or more
large displays. The control system cabinets will typically be
located in a computer room or cable spreading room adjacent,
above, or below the new control room, with data communi-
cations interfaces serving the consoles and workstations.
The ISO 11064 standards (Parts 1 through 8) offer a sound
methodology in the design of a new control room. Their
emphasis is on the design of a new control room in the context
of a new plant, but they also describe design processes that
can be used in designing a new control room as a retrofit in
an existing facility.
Using a standard design methodology, as shown in
Figure 4.3e, will improve safety, quality, and reliability when
applying modern digital system technology. The roles and
responsibilities of operators and machines can be modified
1081_C004.03.fm Page 623 Monday, August 22, 2005 2:44 PM

4.3 Control Center Upgrading 623

BASELINE EVALUATION
Basic layout
Task analysis
Functional allocation
Operational feedback
Economic analysis

CONCEPTUAL DESIGN
Initial drawings and specs
Virtual reality models
Mockups
Simulation

DETAILED DESIGN
Final drawings and specs
Control room layout
Workstation/Console layout
Design displays and controls
Support systems (HVAC, etc.)

VALIDATION
Construction/Simulation
Task walkthroughs
Event walkthroughs
Procedure validation
Operator training
Start-up
OPERATION AND
MAINTENANCE
Benchmarking
Self-assessment
Continuing training
Problem reporting
Corrective action
Modifications

FIG. 4.3e
General design process for new control rooms.

and tasks and functions reallocated to achieve a higher per-
formance standard. An increased reliance on automation can
significantly alter the role of operators by reducing their task
to vigilance over a constant process, while also greatly
expanding their role during system upsets to one of correc-
tive action through cognition, diagnosis, and appropriate
manual responses. If a new control room is under consider-
ation, particular attention has to be paid to ensuring that any
changes in roles and responsibilities of machines and oper-
ators from the old control room to the new one continue to
meet or exceed the goals and objectives outlined in the
baseline evaluation. Without a careful design process, unin-
tended functions can be created with potentially negative
consequences.
Basic ergonomic principles should be applied in the
design of control rooms. Ergonomic design principles include:
• Use a human-centered design approach. Design for
basic physical limitations, but also emphasize human
cognitive strengths such as perceptual, problem-solving,
and decision-making abilities.
• Improve design through iteration. Repeat design eval-
uations until functional and performance goals are
achieved.
• Start with the baseline evaluation performed on the
original control room, and revise through each design
iteration.
• Design error-tolerant systems. Allow for human error,
and provide interlocks, alarms, and overrides where
appropriate.
• Ensure user participation. The most knowledgeable
asset on the design team can be the control room oper-
ator. Add system and process engineers, ergonomists,
architects, and industrial designers to form an interdis-
ciplinary design team.
TECHNOLOGY ADVANCES
Technology advancements in recent years have enabled a
state-of-the-art approach to control room design. Compact
workstations, large display panels, soft controls, fixed and

© 2006 by Béla Lipták

1081_C004.03.fm Page 624 Monday, August 22, 2005 2:44 PM
624 Control Room Equipment
selectable displays, advanced alarm systems, and computer-
ized procedure systems greatly enhance safety, reliability, and
efficiency.
A modern control room includes compact workstations,
a safety console for plants that require one, and furniture and
rest areas. A large display panel (LDP) can also be provided.
Key features that support the ability of the operating crew to
maintain efficient and safe plant operation include:
• Full-function workstations supporting direct plant con-
trol and monitoring by one or more system operators
• An identical workstation supporting normal monitor-
ing and crew coordination functions of a control room
supervisor and serving as a backup to the operator
workstations
• An LDP providing overall plant operational and safety
assessment
• A safety console (for those industries with safety
requirements) providing control capability for all
safety-related components independent of the work-
stations supporting safe plant shutdown even in the
event of complete workstation failure
Advantages of this control room layout, shown in
Figure 4.3f, include enhanced communication between oper-
ators, operational facilities for all expected crew members,
good visibility of the LDP, ease of accommodating design
and job allocation changes, and convenient access and
egress routes. Layouts will vary depending on the number of
Large display panel
Compact
workstations
FIG. 4.3f
Sample control room layout.
© 2006 by Béla Lipták
systems in the process plant that are monitored and controlled
in a main control room. If a site has multiple process plants
that are independent islands, but still controlled from one
central control room, then the control room layout may
employ multiple sets of compact workstations, depending on
operator and supervisory tasking.
The LDP is a wall-mounted overview display, which
includes static and dynamic elements. High-resolution, tiled
projection systems are available today with seamless bor-
ders between tiles. The fixed display section of the LDP
provides continuous, parallel display of key alarm, compo-
nent, system, and parameter information. This complements
the workstation HMI with a spatially dedicated graphical
depiction of the plant. A variable display section allows
operators to display pertinent information selectively to
support crew coordination. A sample LDP design is shown
in Figure 4.3g.
Each main control room workstation provides devices for
access to all information and controls necessary for one person
to monitor and control all processes associated with plant oper-
ation and safety. This includes both safety and nonsafety sys-
tems. A sample workstation layout is illustrated in Figure 4.3h.
Each workstation contains the following:
• One alarm VDU with trackball user interface
• Multiple VDUs supporting process monitoring or elec-
tronic procedures with trackball user interface
• Multiple flat panel displays used as soft controllers for
process and component control; each works in con-
junction with one VDU, using a touch-sensitive user
interface
• Dedicated, diverse push buttons for manual safety sys-
tem actuation
• Laydown area for logs, drawings, backup paper pro-
cedures, etc.
The major advantages of the compact workstation
approach are its (1) operational and design flexibility, (2) com-
pactness and simplicity, (3) ability to accommodate changes
cost-effectively, and (4) provision of an enhanced integrated
environment for a computerized procedure system (CPS) and
operator aids.
Workstations should allow simultaneous access to plant
information through selectable displays on multiple VDUs
per workstation. A wide variety of display formats should
support system mimics, major plant functions or conditions,
technical data sheets, trends and graphical information, and
application program access. All are designed to support spe-
cific operator functions. Multiple methods should be pro-
vided for convenient access to the display set, including nav-
igational access through menus, direct access through format
chaining from other displays (or alarms and procedures), and
a dedicated mechanism such as function buttons or voice
entry. A major function of the VDU displays is to provide a
soft control link allowing the operator quickly to select a
 CNMT ENVIRN CNMT ISO REACTIVITY CNTL CORE HEAT REM RCS HEAT REM RCS INV CNTL RCS PRESS CNTL MODE: NORMAL SFSC: SPTA RAD EMISSION VITAL AUX STM FEED HEAT REJ ELEC GEN
Main Safety Unit

© 2006 by Béla Lipták

CNMT FAN CLR PEN Flow PEN Flow RX ROD NATUR Forced AUX Safety CVCS PZR HTR & Spray RLS Path RLS Path EMER D/G Main STM CNDSR T/G
Spray Path ISO Path CNTL Trip CNTL CIR CIR feed feed INJ CHG & LDN INJ INSER COLSS MON & CNTL AUX XFMR T/G CNTL
H2 CEA TRBL PMS TRBL ISO
CVCS CHG & LDN Limit TRBL AAC D/G CNDNST CIR WTR
H2 Purge Safety CVCS Safety SHUTDN S/U Feed RCGV STBY MDS
INJ CLNG CVCS AUX Spray Rx TBN AUX B/D Vital AUX XFMR ATM
RECOM H2 INJ BOR Safety PRI RLF IA TRBL D/G
TRIP TRIP RAD Statn Bat DUMP
IGNTR depress S/G STMNG N-Vital D/G CNTL
TBN
Statn Bat Bypass
Safety depress MSADV
LVL MSSV RAD TBADV Net /
L R MSR B Gross SWYD
22 KV
RWT MSIV TSV TCV
Press H2 Main WATT 345 KV
LVL CEA POSI S/U Rate GEN
Flow F CCW MGN to PWR MTR SWYD
L P POSI Rate MSADV
SUR LVL Oper LMT CREV FBEV CPI RAD
MSSV 345 KV
TK B CI LMT R
1081_C004.03.fm Page 625 Monday, August 22, 2005 2:44 PM

L CS T Temp CR HVAC
SIT RDT Flow
Temp ISO DAM MSIV TSV TCV SAT
CSP 1 T ESW 2A P Press Excit
Heat Rate POSI F Press
PP B LVL MSR A 13.8 KV
CCW PWR LMT R RAD
SC Press P MS
TBV P UAT 4.16 KV
PP B LMT Press P
Hx B L S/G 2
LPSI 13.8 KV 4.16 KV
CCW Hx COLD L VAC PP
1B LVL
Press TBV
Flow T Flow Press
P On RCP 2A
F P LVL CWP A
F LVL Rx PWR
AFIV AFIV AFCV AFWP B
L PWR CET Hot L
Temp SIT CWP B
F RCP F/R N-1E N-1E
Flow 2B ASI T T
T F/R Press 4.16 KV
CST CWP C 13.8 KV
HPSI ASI P CDP A
B
2B CORE AVG AFIV AFCTIV AFWP D CWP D
PWR LP HTR CDP B
T Avg / T Ref RCP F/R Flow
Flow F PWR RCP 2B Press CWP E
SI L LVL Temp F/R CDP C 480 V
T F AF
DNBR P LVL LC
Cold LVL CWP F 1E
DNBR Press P S/G 1 AFIV AFCTIV AFWP A
Press L CDP D L D/G
LVL
CCW P SM LVL L 1E
Flow F Deaerator
SUR L LVL SM Cold T Flow Press 4.16 KV
RCP 1B CST LC
TK A L F P A
SIT SYNC
AFIV AFCV AFWP C 480 V
CSP 2 T Temp ESW 1A Scope
RAD CET Hot
PP A RCP F/R FWP A FWBP A
CCW R T T AFIV
SC F/R
Hx A PP A FWP B FWBP B
LPSI UPS
1A CCW Hx
LVL FWP C FWBP C
Press HP HTR N-1E
Flow LVL
L L RCP 1A RAD
D/G
P R LVL S/U FWP LVL 120 V AC
F LVL T
CNMT RCP F/R L L
L Ion
Temp SIT RECIR Rx Cold F/R LDN 120 V AC
F SFP Exch
1B SUMP Cavity Hx
Flow BAM PP1 125 V DC
T RWT
HPSI VCT
LVL
2A LDNCV BAM PP2 125 V DC
L
CHG PP1
Flow F RMWT
RMW PP1
CHG PP2
REGEN CHGCV
Hx RMW PP2
CHG PP3

FIG. 4.3g
Large display panel. (Courtesy of Westinghouse–CENP & KEPRI.)
4.3 Control Center Upgrading
625
1081_C004.03.fm Page 626 Monday, August 22, 2005 2:44 PM
626 Control Room Equipment
FIG. 4.3h
Typical workstation design. (Courtesy of Westinghouse–CENP & KEPRI.)
component or process control on the soft controllers directly
from display pages.
“Soft controls” should utilize flat panel displays to emu-
late the physical switches and manual/auto stations that pop-
ulate conventional plant control panels. Use of software-based
control allows a standard interface device to assume the role
of numerous physical devices. This has the advantage of
allowing operator access to all plant controls from a single
workstation, design flexibility, the ability to accommodate
changes easily, and simplification of hardware procurement
and maintenance. Various design concepts can support control
of multiple safety and nonsafety divisions from the same
workstation device, while maintaining the single-failure-proof
reliability of conventional channel separation and indepen-
dence to support safety system requirements such as those
called out in IEEE-603 (1998) “Standard Criteria for Safety
Systems for Nuclear Power Generating Stations” and ISA
84.01 (1996) “Application of Safety Instrumented Systems for
the Process Industries.”
An advanced alarm system can be provided to improve the
annunciation process, by incorporating methodologies that:
• Reduce the total number of alarms with which the
operator must cope
• Distinguish between true process deviations and sen-
sor failures
• Minimize the occurrence of “nuisance” alarms
• Prioritize the relative importance of alarms so the
operator can focus on the most critical alarm condi-
tions first while deferring less critical alarm condi-
tions
• Determine the impact of alarms on plant operations
and distinguish these from lower-level system alarms
Highest priority alarms, such as those for critical functions,
are presented in fixed locations on the LDP. All alarms are
presented in list form on a dedicated workstation VDU as well
as through relevant locations in the VDU display hierarchy.
© 2006 by Béla Lipták
COMPUTERIZED PROCEDURE SYSTEMS
Computerized procedure systems (CPSs) are another signif-
icant technology development in modern control rooms,
which take advantage of state-of-the-art technology to pro-
vide benefits in the human–machine and control room inte-
gration areas (Figure 4.3i).
The purposes of an online, data-driven, cathode ray tube
(CRT)-based CPS are the following:
• To guide the user step by step through the procedures
by monitoring the appropriate plant data, by process-
ing the data and by identifying the recommended
course of action.
• To provide the parallel information necessary to allow
the user to assess other plant conditions that may
require attention, such as, for example, notes, cautions,
and foldout page items.
The computer monitors and evaluates large amounts
of information quickly and efficiently. Procedure informa-
tion is online and is updated essentially continuously.
Hence, the operator becomes more vigilant because a large
amount of procedurally required information is immedi-
ately available. The operator’s mental loading is reduced
because all required procedural information is displayed,
including, for example, the status of the current high level
step.
The human user’s primary role in a CPS environment
is to monitor the progression through the plant procedures
while maintaining a clear picture of plant state, to take
control actions on the control board when they are required
and to watch for unsafe plant conditions. The user should
retain both authority and responsibility for plant opera-
tion. A CPS is user paced, that is, the system should not
advance to a procedure step, a note, caution, or foldout
page item, or a procedure unless instructed to do so by the
user.
1081_C004.03.fm Page 627 Monday, August 22, 2005 2:44 PM

4.3 Control Center Upgrading 627

Computerized Procedures - COMPRO

Displays Access Procedures Print Log Quit COMPRO
Subcriticality
Core Cooling
Heat Sink
FOLDOUT PAGE
Integrity
Containment
Inventory

Procedure: E-0 Title: Reactor Trip or Safety Injection Rev. 0 ( )

Initiated Action
10 Verify INR Pump RUNNING: (Violated) Thu. Aug 12 11:13:14 1333
11 Verify Raw Water Pumps RUNNING: (Violated) Thu. Aug 12 11:15:06 1415
12 Verify Containment and Annulus Cooling: (Violated) Thu. Aug 12 11:15:16 1344

Step 13: Verify if Annulus should remain isolated: (VIOLATED)

a. Annulus pressure at 35 mBar a. Verify that Annulus is vented:

1) Fan KHV 10 RUNNING
Annulus Pressure
2) PCV 6402 L,K - OPEN
NOT AT 0.035 bar +0.005 bar, -0.002 bar 3) Valves PCV 6453 A,B - OPEN
Pressurizer Pressure IF NOT, vent the annulus
Go to Step 15.
NOT AT Annulus Pressure +1.0 +0.2, -0.1 bar Fan KHV 13
NOT RUNNING
Fan KHV 13 Breaker

NOT CLOSED
Valve PCV 6402L
OPEN
Valve PCV 6402K
NOT OPEN
Annulus Discharge Valve PCV - 6453A
NOT OPEN
Annulus Discharge Valve PCV - 6453B

14 Check if Main Steamlines Should Be isolated:

15 Verify Containment Spray Not Required:
16 Verify JSI Flow:
17 Verify LSN Pump Cooling:

Continue with Step 13

Go To E-0 15

FIG. 4.3i
Computerized procedure system. (Courtesy of Westinghouse–CENP.)

A CPS can operate on a two-CRT workstation such that
the required procedural information always appears on the
first screen and supporting or supplementary procedural
information appears on the second screen. Access to the
supporting information should be through pull-down menus
located along the top of the main screen.
The benefits of a CPS include:
• The computer and the operator complement each other
for a more accurate implementation of the procedures,
resulting in enhanced situation assessment by the
operator.
• The system simultaneously monitors multiple plant
parameters.
• The system brings all procedural information to one
location.
• The system provides detailed record-keeping capabil-
ity of the procedure execution.
PHASED APPROACH
A phased approach to upgrading the control room may be
economically attractive. In this approach, it is important to
recognize whatever design and operating constraints may be
in place. The control room to be upgraded is assumed to be
in service, and should continue to meet the business goals
set by the owner.
The entire control room can be upgraded in phases, over
time, according to whatever drivers are selected. The scope
and schedule of each phase is optimized when it is consistent
with the overall cost–benefit analysis of the entire upgrade,
which may take years. If obsolescence issues are not acute,
but are slowly accumulating, and the plant is running safely
and meeting business objectives, then upgrades can be
applied to individual systems or groups of systems while the
plant is running or during routine maintenance outages.
If a phased approach is used, then a long-range strategic
I&C modernization plan should be developed before any
system or component upgrades can significantly impact the
control room. Failure to do so will not have any impact on
a particular system upgrade, but in the overall scheme, it can
increase the total cost of the finished control room. The long-
range plan will provide a conceptual design for the finished
plant and control room, and it will provide a scope, schedule,
and budget for each phase so that they are scheduled in the
most cost-beneficial sequence. Each phase will account for
the set of systems and components that should be upgraded,
taking into account time-to-obsolescence and grouping of
systems and components so duplication or rework on later
phases is avoided. Obsolescence can be successfully applied

© 2006 by Béla Lipták

1081_C004.03.fm Page 628 Monday, August 22, 2005 2:44 PM
628 Control Room Equipment
in arguing for a comprehensive upgrade plan. Not all the
original analog I&C systems will become acutely obsolete
at the same time.
In the original analog control room, a unique treatment
of indications and controls for each plant system was the
norm. Panels were typically designed to support collections
of meters, recorders, switches, and controllers grouped by
plant system. It is important to avoid unique upgrades for
each plant system. If unique digital solutions are applied over
time, the result will be a muddled set of DCS, PLC, and other
operator interfaces in the control room. All the operational
goals of the plant upgrades will not only go unfulfilled but
will worsen when realized in total.
Figure 4.3j illustrates the modernized plant. The func-
tional layers are still the same, but there is a significant change
in the technology applied in each layer. Figure 4.3j can be
considered a hybrid digital/analog plant. The left side of this
figure shows digital systems; the right side shows the original
analog components. As more plant systems are upgraded,
more of Figure 4.3j becomes digital. Hardware and software
diversity may be applied for safety systems in each layer
where required by regulatory agencies.
The key point in Figure 4.3j is that new I&C systems are
expandable horizontally in this perspective, using a building-
block approach that applies DCS or PLC technology linked
by network communications technology, such as Ethernet,
fieldbus, or any other standard that is supported by the man-
ufacturer. This point is essential for implementing a cost-
effective phased control room upgrade, where systems are
expanded until obsolescence issues are resolved and modern-
ization goals are realized.
The I/O layer employs subracks that can be field-
mounted or mounted in cabinets or panels in the control
room. The location of the new subracks depends on a number
of factors, such as communication constraints (distance,
bandwidth, number of allowable nodes) and the impact on
Internet
Enterprise
Operations
Maintenance/
Engineering
Control/
Computing
I/O
Fieldbus
Plant sensors and control elements
FIG. 4.3j
Hybrid I&C architecture.
© 2006 by Béla Lipták
cable costs. To optimize cable costs, the best place to mount
I/O subracks is within reach of the field cables that were
originally terminated on or near the old analog devices.
The control/computing layer employs DCS or PLC proces-
sors or a combination of both. Equipment selection should
allow data archiving and computational servers to be added to
this functional layer and integrated into the whole control and
computing platform system. Hardware and software integration
can be expensive and time-consuming, so it should be consistent
with one set of standards.
Note that original control room meters can still be used
with a new DCS/PLC platform using the new I/O sub-
systems. This design feature is useful when an entire process
system is upgraded, where video display units cannot replace
every system switch, light, meter, or annunciator. For exam-
ple, a small-scale DCS can replace a turbine/generator elec-
trohydraulic control (EHC) system with one or two main
VDUs in the place of the original operator interface and still
allow connections to original devices in other locations. If
all original EHC interface devices in this example are sched-
uled for replacement with VDUs, the potential exists for
other plant systems to be caught up in the EHC upgrade
simply because the new VDUs take up more panel space
than the original meters and switches.
If any special applications are required, such as a data
archiving agent or any plant performance calculation pack-
ages, plan ahead and select a DCS/PLC hardware and software
platform that can support the special application hardware and
software. Pay close attention to database integration issues,
because a central database is the strength of a DCS. If an
original plant data acquisition system can be connected to a
new DCS and the data integrated into the central database,
then it will be possible to display and archive the data seam-
lessly, transparent to the operator, without a new front end for
those data points.
Network communications is utilized between all layers.
The network topology is optimized for cost and connectivity
options, and the first phase of the modernization effort should
be carefully designed so that future phases are accounted for
with at least 100% spare connectivity. Spare connectivity
should support copper and fiber media options. When pulling
new fiber-optic cables, select termination locations that sup-
port the long-range plan, and pull as many fibers as possible
in each cable run (limited by budget or raceway fill).
The operations layer in Figure 4.3j is the most constrained
layer in the phased upgrade approach. This layer is constrained
by the physical layout and fundamental design of the existing
control room. For example, the breakfront panels shown in
Figure 4.3b are designed for a standing operator, and indica-
tions and controls are laid out by groups associated with major
plant system functions. HMI resources such as flat panel dis-
plays have to be designed so that the basic information zones
of the control panels can remain intact. If a particular infor-
mation zone contains vertical meters and trend recorders, then
flat panel displays should be sized to fill that zone (with redun-
dancy if possible), and the DCS or PLC system should be
1081_C004.03.fm Page 629 Monday, August 22, 2005 2:44 PM
FIG. 4.3k
Feedwater heater indicators and controls.
programmed with a display page that carries the same infor-
mation with the same readability of the replaced components.
Figure 4.3k is a good example of some information
zones on the control room panel shown in Figure 4.3c.
Shown here are four zones. The zone on top is a group of
feedwater heater level indicators. The middle-left zone is a
pair of heater drain tank level indicators while the middle-
right zone consists of three condenser vacuum indicators.
The bottom zone is a set of indicating hand switches that
indicate and control valve position. All of these instruments
are connected to obsolete transmitters in the field, which are
being upgraded using fieldbus technology. New controllers
are being installed, and an integrated display can be con-
nected to the system for use by operators in the control room.
The original indicators in Figure 4.3k can be maintained as-
is using analog and digital I/O points connected to the con-
troller I/O subrack, but this upgrade provides a point of entry
into the control room for a modern HMI interface, which is
inevitable given the I&C obsolescence issues in the plant.
The feedwater heater system is a good pilot project for this
technology, where its information zone remains intact using
flat panel displays.
Note the size of the meters in Figure 4.3k. The character
size, color, luminosity, and arrangement are designed to allow
© 2006 by Béla Lipták
4.3 Control Center Upgrading 629
Feedwater heater level
Heater
drain Condenser
tank vacuum
level
Bleeder trip valve position
indication and control
FIG. 4.3l
Feedwater heater information zone.
readability from 15 ft away, where the control room super-
visor sits. This is a firm constraint for the system, because
operator tasking is designed to allow one control room super-
visor to stand back and take in all of the control panel indi-
cations simultaneously from a central location in the control
room, while an operator can stand close to these indicators
and manipulate them manually.
The information zone “map” for these instruments is
shown in Figure 4.3l. The information is of relatively low
density. These parameters are used by control room operators
during normal operations, including start-up and shutdown.
The operators’ task during normal operations is to monitor
these variables during routine watch-standing operations.
Their task during alarm conditions is to diagnose the cause
of the alarm and verify automatic control actions have taken
place and/or to take manual action as required by written
procedures, so that the system parameters are returned within
normal operating limits.
Figure 4.3m shows the same information zone in a modern
display example, which can also be applied in a mockup (any
scale). This figure shows two flat panel displays, designed for
installation in the place of the original instruments. The con-
cept is to program each flat panel with a “default page” that
arranges the same variables in a similar fashion to the original
arrangement, with font sizes as large as or larger than the
characters on the original meters. Because this is a redundant
design, each flat panel can be set to display any other page
in the display hierarchy.
This design maintains the same readability and operator
tasking as the original design, while offering powerful new
interfaces to the operator. The control room supervisor can
continue to stand back and take in all indications during nor-
mal and emergency operations, while the control room oper-
ator can manually page through the various display pages
1081_C004.03.fm Page 630 Monday, August 22, 2005 2:44 PM

630 Control Room Equipment

The feedwater heater displays in the above example are

a starting point for the entire panel in Figure 4.3c. As more
channels of information are added to the DCS/PLC system,
Feedwater more displays can be added to the same panel, or larger
heaters
level displays can be installed with more information available per
display.
11 A 11 B 11 C 13 A 13 B

PLANNING AHEAD

The first phase in a phased control room upgrade project

should prove that the overall conceptual design for the control
12 A 12 B 12 C 15 A 15 B 16 A 16B room can be implemented safely and effectively. Once it is
4/24/01 Back Fwd Main proven that the upgraded system has a positive impact on
Alarm Trouble Print
14:04:43 Menu
control room operations with improved reliability and cost-
effectiveness, then the system can be expanded to all systems
in the control room. The pilot approach allows training of
engineers, technicians, and operators to commence without
a massive undertaking, and valuable lessons learned can be
applied to all disciplines on future phases (design, procure-
ment, start-up, and operations and maintenance). The key is
to purchase a digital I&C platform that can be applied on a
11 HTR 12 HTR 11 CNDSR 12 CNDSR 13 CNDSR smaller-scale project then expanded into the rest of the I&C
DRN TK DRN TK VACUUM VACUUM VACUUM
Bleeder
systems in the plant.
Close Open Close Open Close Open Close Open
trip
valves 1-ES-1430-BTV 1-ES-1436-BTV 1-ES-1440-BTV 1-ES-1440-BTV

Close Open Close Open Close Open Close Open Close Open HMI STANDARDS
1-ES-1432-BTV 1-ES-1434-BTV 1-ES-1436-BTV 1-ES-1442-DTV 1-ES-1444-DTV

4/24/01 Back Fwd Main

Alarm Trouble Print
14:04:43
FIG. 4.3m
Upgraded feedwater heater displays.
available on the flat panel using a touch or trackball interface.
Also, applying DCS technology for this interface supports
additional flat panels or VDUs in other parts of the control
room, such as an auxiliary panel or on the control room super-
visor’s desk. Although the default page is designed to be sim-
ple and readable consistent with the original panel design and
operator tasking, the system also supports a full range of
object-oriented graphic displays, event logs, archives, alarm
management, and testing provisions.
Maintaining the original information zone design concept
is only the start of any control room upgrade effort. Improve-
ments in safety, reliability, readability, and a reduction in the
potential for operator error should also be goals of the project.
The use of a digital DCS or PLC platform enables the realiza-
tion of these additional goals. Variations in colors, fonts, reverse
video, and flashing objects are available with digital technology.
New systems can detect an alarm on a failed channel (out of
range high or low). Also, technology developments such as
automatic alarm prioritization and computerized procedures
may be implemented in a new system such as this one.
It is essential that the long-range plan account for the impact
Menu on the operator, and that an HMI standard be applied consis-
tently from start to finish. Flat panels, video display units,
workstations, and consoles should be uniformly designed,
and software should be standardized so that all system indi-
cations and controls are seamless and transparent in a com-
mon interface style. If an operator has to move to a specific
piece of HMI hardware for each plant system or point-and-
click on different icons for each plant system, then the oppor-
tunity to improve safety and reliability while reducing oper-
ating costs is diminished. The only exception to this rule is
when diverse indications and actuations are required, such as
for manual safety system actuations (e.g., reactor trip).
HMI attributes such as color codes, abbreviations, fonts,
graphic elements, display sizes, and readability should all be
consistent. A human-factors engineering (HFE) program
should develop standards and procedures that will be coupled
with an operator and maintenance technician training pro-
gram, consistent with the long-range plan.
While the goals of a control room upgrade are to elim-
inate obsolescence, reduce maintenance and operating costs,
and improve safety and reliability, the basic control room
panel and furniture layouts and operating and maintenance
procedures will be constrained throughout the phased
approach. However, the control room panels and furniture
can still be altered in a local sense. It is acceptable to
introduce different HMI methods in clearly distinct contexts.
For example, it is acceptable to add modern soft controls

© 2006 by Béla Lipták

1081_C004.03.fm Page 631 Monday, August 22, 2005 2:44 PM
FIG. 4.3n
Demonstration control room. (Courtesy of Westinghouse Electric
Company.)
techniques into conventional control rooms for distinct oper-
ations such as water treatment. As operators become familiar
with the new HMI, the designer can be confident they will
accept transitioning to the modern HMI for more critical
systems. At any point in this transition process, it is impor-
tant to ensure that operators are within the same HMI context
(conventional or soft) for any particular plant system.
Figure 4.3n illustrates design concepts for panels, furni-
ture, and a large display that can be evaluated for use in any
analog control room. Panels can be modified and still mix
manual controls, analog meters, and flat panel displays. Fur-
niture can be modified to mount flat panels on arms that can
be manipulated to suit operator tasks. For example, if an
operator needs a line of sight to the control panels during
routine operations, then the flat panel can swing out of the
way. If an alarm requires some diagnosis, then the operator
can swing the flat panel back into view and perform a specific
task, or use it in combination with the large display panel in
a supervisory role.
Gross design problems in the control room should not be
applied as constraints in the phased approach. For example,
if a critical process variable is indicated on one panel and
controlled on another in a way that does not allow the oper-
ator to observe and control the process simultaneously within
acceptable HFE practice, even if the operator has learned to
work around the problem, then the control and indication
should be colocated in the new interface. This is a good
example of how a VDU in each information zone can resolve
old design issues.
MAINTAINABILITY
Improved maintainability of the plant and control systems in
particular should be a significant goal of a control room
upgrade. Information and control systems should be purchased
© 2006 by Béla Lipták
4.3 Control Center Upgrading 631
with diagnostic aids and functions that support the ability to
store short-term, local data logs and the ability to off-load
data to archival systems. In addition to normal process infor-
mation, there should be pages of information related to pro-
cess events (warnings and alarms), diagnostic events (system
and component faults), and maintenance information. This
information should enable an operator to detect and mitigate
an event immediately, and call the maintenance department
to investigate, troubleshoot, and perform corrective actions
if necessary. Corrective actions should be more timely and
effective on the control system itself as well as on plant
equipment.
Networks allow multiple video displays in and around
the control room. When an analog plant was constrained to
field- or panel-mounted indications and controls, the only
data available to the maintenance or engineering department
were real-time data in the control room, or sparse, historical
data by way of manual operator logs. Intermittent problems
were usually very difficult to repeat, diagnose, and correct.
A control room upgrade should fill this void in the mainte-
nance and engineering departments. Displays should be set
aside for these departments in or adjacent to the control room,
with secure access. Control system access should be con-
trolled first by physical security, then by password security.
Maintenance and engineering displays should provide
enough data to understand a plant process event or a control
system event. Digital inputs and outputs should be captured in
a sequence of events (SOE) log. Maintenance and engineering
displays should also allow users to navigate all available infor-
mation and settings on the system, including the ability to
change settings, start and stop programs or tasks, and run sys-
tem diagnostics in an offline mode. Modes should be controlled
by password and/or key switch inputs to the system.
Displays on the main control panels should be limited to
information and controls that are related only to normal and
emergency plant processes. Physical security should limit
access to operator displays to qualified plant operators only.
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