NFPS Offshore Compression Complexes Project COMP2

COMPANY Contract No.: LTC/C/NFP/5128/20

CONTRACTOR Project No.: 033734

Document Title

:

HFE WORKPLACE DESIGN SPECIFICATION FOR CP6S AND CP7S COMPLEXES

COMPANY Document No.

: 200-20-SH-SPC-00011

Saipem Document No.

: 033734-B-D-30-SPM-LP-S-10024

Discipline

: HSE&Q

Document Type

: SPECIFICATION

Document Category/Class

: 1

Document Classification

:

INTERNAL

A

08-Jun-2023

Issued for Review

Guruh P Aji

Hardeep Singh

Luminita Oprescu

Guruh P Aji Digitally signed by Guruh P Aji

DN: cn=Guruh P Aji, o, ou, email=guruh.permonoaji@saipem.com, c=ID Date: 2023.06.12 15:50:56 +08’00’

Vijayakumar R

Digitally signed by Vijayakumar R Date: 2023.06.12 17:44:43 +08’00’

Oprescu Luminita

Digitally signed by Oprescu Luminita Date: 2023.06.12 18:15:03 +08’00’

REV.

DATE

DESCRIPTION OF REVISION

PREPARED BY

CHECKED BY

APPROVED BY

Saipem S.p.A.

Company No._Rev. 200-20-SH-SPC-00011_A

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REVISION HISTORY

Revision

Date of Revision

Revision Description

A1

A

25-Apr-2023

08-Jun-2023

Issued for Inter-Discipline Check

Issued for Review

HOLDS LIST

Hold No

Hold Description

Company No._Rev. 200-20-SH-SPC-00011_A

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TABLE OF CONTENTS

1

2

3

4

5

INTRODUCTION … 6

1.1 PROJECT OBJECTIVE … 6 1.2 PROJECT SCOPE … 6

DEFINITIONS AND ABBREVIATIONS … 8

2.1 DEFINITIONS … 8 2.2 ABBREVIATIONS … 9

REFERENCE, RULES, CODES AND STANDARDS … 11

3.1 ORDER OF PRECEDENCE … 11 3.2 COMPANY PROCEDURES POLICIES & STANDARDS … 11 3.3 PROJECT DOCUMENTS (FEED) … 11 3.4 PROJECT DOCUMENTS (DETAILED DESIGN) … 12 INTERNATIONAL CODES AND REGULATIONS… 13 3.5

PURPOSE AND SCOPE … 14

4.1 PURPOSE … 14 4.2 SCOPE … 14

ACCESS TO EQUIPMENT AND MOVING AROUND FACILITY … 15

5.1 ESCAPE ROUTES … 15 5.2 EXITS … 15 5.3 DOORS … 15 5.4 DOORS AND HATCHES ON ESCAPE ROUTES … 16 5.5 WALKWAYS AND WORKING PLATFORMS … 17 5.6 STAIRS, LADDERS AND RAMPS … 20

5.6.1 General … 20

5.6.2 Stairs … 20

5.6.3 Fixed Ladders … 22

5.6.4 Ramps … 28 5.7 WORKSPACE AND ACCESS … 30

5.7.1 Workspace … 30

5.7.2 Deck Surfaces : Slip and Trip Hazards … 36

5.7.3 Access … 36 5.8 VALVES … 38

5.8.1 General … 38

5.8.2 Manual Valve Categories … 38

6

WORKING ENVIRONMENT … 42

6.1 LIGHTING… 42 6.2 THERMAL ENVIRONMENT … 43

6.2.1 Temperature … 43 6.3 VIBRATION… 43

6.3.1 Whole Body Vibration … 43

6.3.2 Hand-Arm Vibration … 43 6.4 NOISE REDUCTION AND CONTROL … 43

7

EQUIPMENT … 44

7.1 GENERIC HFE REQUIREMENT … 44

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7.2 MATERIAL HANDLING … 47 7.3 LARGE EQUIPMENT AND ROTATING MACHINERY … 47

7.3.1

Local Displays and Controls … 48 7.4 OVERSIDE AND SUSPENDED WORK … 48 7.5 LOCAL INSTRUMENTS … ERROR! BOOKMARK NOT DEFINED.

7.5.1 Moving To and Workspace Around the Local Instruments Locations … 48

7.5.2 Displays and Controls … 49 7.6 PIPEWORK AND VALVES… 49

7.6.1 Controls and Displays … 49

7.6.2 Spacing … 49 7.7 TEST AND VALVES … 49 7.8 COMMUNICATION SYSTEMS … 50

7.8.1 System Requirements … 50

7.8.2 Speech Transmission and Reception Equipment … 50

7.8.3 Audibility and Recognition of Signals and Alarms … 51

7.8.4 Evacuation Alarm Systems … 51

8

SIGNAGE AND EQUIPMENT LABELLING … 53

8.1 CHARACTERS AND NUMERALS … 53 8.2 PIPE LABELLING… 53 8.3 ELECTRICAL WIRE AND CABLE LABELS … 53 8.4 HAZARD SIGNS … 53 8.5 TEXT, WORDING AND SYMBOL USE FOR SIGNS AND EQUIPMENT HANDLING … 53

9

CONTROL ROOMS AND CONTROL PANELS… 55

9.1 VISUAL DISPLAYS … 55

9.1.1 Distance and Angles … 55

9.1.2 Safety Critical Controls and Displays … 59

9.1.3 Spacing … 60

9.1.4 Sequence and Position … 60

9.1.5 Display Convention … 60

9.1.6 Operability … 60 9.2 MINIMUM REQUIREMENTS FOR PROCESS CONTROL SYSTEMS … 63

9.2.1 Monitors … 63

9.2.2

Input/Pointing Devices… 63

9.2.3 Printers … 63

9.2.4 Dynamic Characteristics… 63

9.2.5 System Security … 63

9.2.6 Data Integrity … 64

9.2.7

Information Presentation … 64

9.2.8 Alarm Presentation … 64 9.3 VISUAL ACCESS FOR VISUAL DISPLAY UNITS … 65

9.3.1 Visual Display Units and Touchscreen Displays and Controls … 67 9.4 GENERAL LABEL REQUIREMENTS FOR DISPLAYS AND CONTROLS … 68

9.4.1 Specific Requirements for Fire and Gas Panels … 69

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9.4.2 Specific Requirements for ESD and Blowdown Panels … 70

10

ISOLATION AND EMERGENCY SHUTDOWN DEVICES … 71

10.1 ABNORMAL CONDITION DETECTION AND LOCAL INITIATION … 71 10.2 ABNORMAL CONDITION DETECTION AT THE MAIN CONTROL ROOM … 71 10.3 ISOLATION VALVES, BLINDS, SWITCHGEAR AND OTHER DEVICES … 71

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1

INTRODUCTION

The North Field is the world’s largest natural gas field and accounts for nearly all of the state of Qatar’s gas production. The reservoir pressure in the North Field has been declining due to continuous production since the early 1990s. The principal objective of the NFPS Project is to sustain the plateau from existing QG South Operation (RL Dry Gas, RGE Wet gas) and existing QG North Operation (QG1 & QG2) production areas by implementing an integrated and optimum investment program consisting of subsurface development, pressure drop reduction steps and compression. Refer to the figure below for a schematic of the North Field.

Qatargas Operating Company Limited is leading the development of the North Field Production Sustainability (NFPS) Project.

1.1 Project Objective

The objective of this Project includes:

• Achieve standards of global excellence in Safety, Health, Environment, Security and Quality

performance.

• Sustain the Qatargas North Field Production Plateau by installing new Compression Complex facilities CP6S & CP7S in QG south with integration to the existing facilities under Investment #3 program.

• Facility development shall be safe, high quality, reliable, maintainable, accessible, operable,

and efficient throughout their required life.

1.2 Project Scope

The Project Scope includes detailed engineering, procurement, construction, transportation & installation, hook-up and commissioning, tie-in to EXISTING PROPERTY and provide support for start- up activities of the following facilities and provisions for future development. The WORK shall be following the specified regulations, codes, specifications and standards, achieves the specified performance, and is safe and fit

purpose in all respects.

for

Offshore

‐

‐

CP6S and CP7S Compression Complexes that are part of QG-S RGE facilities as follows:

• CP6S Compression Complex

• Compression Platform CP6S, Living Quarters LQ6S, Flare FL6S

• Bridges BR6S-2, BR6S-3, BR6S-4, BR6S-5

• Bridge linked Tie-in to RP6S

Production from existing wellheads (WHP6S & WHP10S) and new wellhead (WHP14S) are routed via riser platform RP6S to compression platform CP6S to boost pressure and export to onshore via two export lines through the existing WHP6S pipeline and a new 38” carbon steel looping trunkline from RP6S (installed by EPCOL). CP6S is bridge-linked to RP6S.

• CP7S Compression Complex

• Compression Platform CP7S, Living Quarters LQ7S, Flare FL7S

• Bridges BR7S-2, BR7S-3, BR7S-4, BR7S-5

• Bridge linked Tie-in to RP7S

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CP7S shall receive production from existing wellheads (WHP5S & WHP7S) and new wellhead (WHP13S). There is only one export line for CP7S through the existing export pipeline from WHP7S. CP7S is bridge-linked to RP7S.

RGA Complex Destressing

Migration of the Electrical power source, Telecoms, Instrumentation and Control systems from WHPs and RPs hosted by RGA to the respective Compression Complexes listed below:

• WHP6S, WHP10S, WHP14S, RP6S and RP10S to CP6S Compression Complex

• WHP5S, WHP7S, WHP13S and RP7S to CP7S Compression Complex

Destressing of Telecoms, Instrumentation and Control system in RGA Complex Control Room, which would include decommissioning and removal of telecom system devices and equipment that would no longer be required post migration and destressing activity.

Onshore

An Onshore Collaborative Center (OCC) will be built under EPC-9, which will enable onshore based engineering teams to conduct full engineering surveillance of all the offshore facilities. The OCC Building will be located in Ras Laffan Industrial City (RLIC) within the Qatar Gas South Plot. MICC & Telecommunication, ELICS related scope will be performed in the OCC building.

Figure 1.2.1: NFPS Compression Project COMP2 Scope

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2 DEFINITIONS AND ABBREVIATIONS

2.1 Definitions

Definition

Description

COMPANY

Qatargas Operating Company Limited.

CONTRACTOR

Saipem S.p.A.

DELIVERABLES

FACILITIES

MILESTONE

All products (drawings, equipment, services) which must be submitted by CONTRACTOR to COMPANY at times specified in the contract. All machinery, apparatus, materials, articles, components, systems and items of all kinds to be designed, engineered, procured, tested and manufactured, constructed, supplied, permanently installed by CONTRACTOR at SITE in connection with the NFPS Project as further described in Exhibit 6.

fabricated,

A reference event splitting a PROJECT activity for progress measurement purpose.

PROJECT

NFPS Offshore Compression Complexes Project COMP2

SITE

(i) any area where Engineering, Procurement, Fabrication of the FACILITIES related to the CP6S and CP7S Compression Complexes are being carried out and (ii) the area offshore required for installation of the FACILITIES in the State of Qatar.

SUBCONTRACT

Contract signed by SUBCONTRACTOR and CONTRACTOR for the performance of a certain portion of the WORK within the Project.

SUBCONTRACTOR

Any organization selected and awarded by CONTRACTOR to supply a certain Project materials or equipment or whom a part of the WORK has been Subcontracted.

WORK

Scope of Work defined in the CONTRACT.

WORK PACKAGE

The lowest manageable and convenient level in each WBS subdivision.

VENDOR

The person, group, or organization responsible for the design, manufacture, testing, and load-out/shipping of the Equipment/ Material.

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2.2 Abbreviations

Code

Definition

American National Standard Institute

American Society of Mechanical Engineers

American Society of Testing and Materials

Blowdown Valves

Bridge

Confined Space Entry

ANSI

ASME

ASTM

BDV

BR

CSE

C1, C2, C3

Category 1, Category 2, Category 3

CCR

CP

dBA

ELICS

EPC

ESD

ESDV

GPA

GTC

GTG

FEED

FL

FWP

HVAC

LCD

LED

LER

Central Control Room

Compression Platform

Decibel-A

Electrical Integrated Control System

Engineering Procurement Construction

Emergency Shutdown

Emergency Shutdown Valves

General Platform Alarm

Export Compressor

Gas Turbine Generator

Front End Engineering Design

Flare Support Platform

Feed Water Pump

Heating, Ventilation, and Air Conditioning

Liquid Crystal Display

Light-Emitting Diode

Local Equipment Rooms

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Code

Definition

LG

LT

LQ

MH

MICC

MOV

NFPS

OCC

PA

PAGA

PPE

PSV

QG

RGA

RLIC

RP

RPE

SCBA

SDV

STHE

TI

TOR

VDU

WHP

Level Gauge

Level Transmitter

Living Quarter

Material Handling

Main Instrumentation and Control Contractor

Motor Operated Valve

North Field Production Sustainability

Onshore Control Centre

Public Address

Public Address and General Alarm

Personal Protective Equipment

Pressure Safety Valve

Qatargas Operating Company Limited

RasGas Alpha Offshore Complexes

Ras Laffan Industrial City

Riser Platform

Respiratory Protective Equipment

Self-Contained Breathing Apparatus

Shutdown Valves

Shell and Tube Heat Exchanger

Temperature Instrument

Terms Of Reference

Visual Display Units

Well Head Platform

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3 REFERENCE, RULES, CODES AND STANDARDS

3.1 Order of Precedence

The following procedures, guidelines, codes, standards, and specifications are referenced within the document and shall be considered as part of this scope of work. When a conflict exists among codes, standards, and project specifications, the most stringent provision shall govern unless otherwise formally clarified and agreed with COMPANY. Conflict among applicable specification and/ or codes shall be brought to the attention of the COMPANY for resolution. COMPANY decision shall be final and shall be implemented. The latest editions of codes and specification effective as on date of contract shall be followed.

The order of precedence shall be followed:

1. Qatari Government and Regulatory Requirements

2. COMPANY Procedures, Policies and Standards

3. Project Specifications

4. Industry Codes and Standards

5. COMPANY and CONTRACTOR’s Lesson Learned

3.2 Company Procedures Policies & Standards

S. No

Document Number

Title

PRT-PRS-PR-C014

Offshore Loss Prevention Philosophy

3.3 Project Documents (FEED)

S. No

Document Number

Title

200-20-PI-SPC-00020

HFE Workplace Design Specification

200-20-PI-REP-00020

HFE Analysis Report (Greenfield Offshore)

200-20-SH-DEC-00002

Technical Safety Basis of Design

200-20-ME-DEC-00001

Mechanical Design Basis

200-20-PI-DEC-00001

Piping & Layout Design Basis

200-20-PI-DEC-00006

Material Handling Philosophy

200-20-EL-DEC-00001

Electrical Design Basis

200-20-PI-SPC-00002

HFE Implementation Plan

200-20-PI-REP-00004

HFE Verification Close Out Report (Greenfield Offshore) Phase 1

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3.4 Project Documents (Detailed Design)

S. No

Document Number

Title

11. COMP2-SPM-LP-SPC-00010

Human Factors Engineering (HFE) Workshop - Terms of Reference (TOR) for CP6S and CP7S Complexes

12. COMP2-SPM-LP-PLN-00001_A

Human Factor Implementation Plan

13. COMP2-SPM-LP-SOW-00001_B

14. 200-20-SH-DEC-00004_A

15. 200-20-SH-DEC-00007_A

Scope of Work (SOW) for Technical Safety & Environmental Studies for CP6S and CP7S Complexes Environmental Design Philosophy for CP6S and CP7S Complexes Noise and Vibration Philosophy for CP6S and CP7S Complexes

16. 200-20-ME-LIS-00001

Master Equipment List for CP6S

17. 200-20-ME-DEC-00002

18. 200-20-PI-DEC-00004

19. 200-20-ME-REP-00001

20. 200-20-EL-DEC-00001

21. COMP2-SPM-LP-SPC-00011

22. 200-20-SH-SPC-00004

23. 200-20-EL-DEC-00006

24. 200-52-TC-DEC-00002

25. 200-52-TC-DEC-00003

26. 200-52-TC-SPC-00033

27. 200-20-CE-SPC-00016

Mechanical Design Basis for CP6S and CP7S Complexes Piping & Layout Basis of Design for CP6S and CP7S Complexes Material Handling Study Report for CP6S and CP7S Complexes Electrical Design Basis for CP6S and CP7S Complexes Ergonomic Study Terms of Reference (TOR) for CCR, OCC Specification and Datasheets for Safety Signs Lighting Design Philosophy for CCR of LQ6S and LQ7S Telecommunication System Philosophy for CP6S and CP7S Complexes Telecommunication Basis of Design for CP6S and CP7S Complexes Specification for PAGA System for CP6S and CP7S Complexes Thermal Insulation Specification for CP6S and CP7S Complexes

28. 200-20-CE-SPC-00001

Panting Specification

29. 200-20-EL-SPC-00011

Technical Specification for Electrical Cable

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3.5

International Codes and Regulations

S. No

Document Number

Title

30. OGP Report No. 454

Human Factors Engineering in Project

Energy Institute

BSI BS ISO 14617-6

Guidance on Human Factors Safety Critical Task Analysis

Graphical symbols for diagrams. Measurement and control functions

ISA 5.5

Graphic Symbols for Process Displays

ASSE A1264.1

ALI A14.3

ASTM F1166 - 07

ASTM F1337 – 10 (2015)

BSI BS EN ISO 11064-1

BSI BS EN ISO 5349-1

ISO 9241-11

ISO 2631

ANSI/HFES 100

Safety Requirements for Workplace Walking /Working Surfaces and Their Access; Workplace, Floor, Wall and Roof Openings; Stairs and Guardrails Systems

American National Standard (ASC) for Ladders - Fixed - Safety Requirements

Standard Practice for Human Engineering Design for Marine Systems, Equipment, and Facilities

Standard Practice for Human System Integration Program Requirements for Ships and Marine Systems, Equipment, and Facilities

Ergonomic Design of Control Centers - Part 1: Principles for the Design of Control Centers

Mechanical vibration. Measurement and evaluation of human exposure to hand-transmitted vibration – Part 1 General requirements

Ergonomic Requirements for Office Work with Visual Display Terminals (VDTs) - Part 11: Guidance on Usability

Mechanical vibration and shock — Evaluation of human exposure to whole-body vibration

American National Standard for Human Factors Engineering of Visual Display Terminal Workstations

NEMA Z535

Safety Alerting Standard

NFPA 72

National Fire Alarm and Signalling Code

ASM Guidelines

Effective Console Operator HMI Design Practices

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4 PURPOSE AND SCOPE

4.1 Purpose

The purpose of this document is to outline the philosophy requirements pertaining to Human Factor Engineering for the EPC phase for the Greenfield and associated Brownfield facilities at CP6 and CP7 compression complexes in COMP2 scope of work. The requirements indicated in this specification are applicable also for the associated Vendor packages.

The principal aim of applying HFE throughout the development phase is to improve health and safety outcomes, by lessening the potential for human errors.

Details of methodology and worksheet template for each HFE activity are described in the Human Factors Engineering (HFE) Workshop - Terms of Reference (TOR) For CP6S and CP7S Complexes. [11].

4.2 Scope

The scope of this document is the NFPS COMP2 compression project facilities. The project scope comprises:

a) Greenfield facilities at CP6 and CP7 compression complexes

b) Brownfield offshore modifications at CP6 and CP7 compression complexes

c) Central Control Room (CCR) and Onshore Control Centre (OCC)

This document is applicable to all the process, utilities and support facilities on the above facilities.

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5 ACCESS TO EQUIPMENT AND MOVING AROUND FACILITY

This Section presents Human Factors requirements in design of facilities and equipment for accessibility and movement [2].

5.1 Escape Routes

1. Areas over 20 ft (6.1 m) long distance shall be provided with at least two exits leading to

escape routes.

2. Primary escape routes shall have a clear passage width (exclusive of handrails, wall- mounted equipment, etc.) of at least 44 in. (1.12 m). This dimension shall be maintained for any stairways in the escape route. The height shall be at least 90 in. (2.286 m).

3. Secondary escape routes shall have a clear passage width (exclusive of handrails, wall- mounted equipment, etc.) of at least 30 in. (760 mm). This dimension shall be maintained for any stairways in the escape route. The height shall be at least 90 in. (2.286 m).

4. Escape routes shall be as direct as possible, avoiding frequent changes of direction and the need to repeatedly ascend and descend deck levels. Where changes in deck level are required, stairs or ramps shall be used rather than ladders.

5.2 Exits

1. A minimum of two exits shall be provided in enclosed, staffed areas where fuel, chemicals, or other flammable materials are used. Emergency exit doors shall be swung to the outside for a smooth emergency evacuation. In areas housing large pieces of equipment such as compressors, the exits shall be located so that it is possible to exit from either side of the equipment.

2. In enclosed structures, a second means of escape shall be provided when the platform’s area exceeds 200 ft2 (18.6 m2). The maximum travel distance between two means of escape shall not exceed 50 ft (15.2 m). The routes shall be arranged so that they do not become compromised by the same fire or other emergency.

3. In substations, Local Equipment Rooms (LERs), and laboratories, a second means of escape shall be provided when containing equipment in excess of 480 V or where potential hazardous or injurious chemical exposure may occur. The maximum distance between two means of escape shall not exceed 50 ft (15.2 m).

5.3 Doors

1. Door openings in means of egress shall have a minimum width of 32 in. (810 mm).

2. For a building/room with a side larger than 3.8m, doors shall be at least 60 in. (1.5 m) from corners (i.e., junctures between two corridors) or from where a single corridor turns a corner, as indicated in Figure 5.1.

3. Door opening shall not be within escape route.

4. Personnel standing space shall be provided in front of door opening area, with at least 750

mm from the edge of the door opening area.

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Figure 5.1 : Door Positioning

5.4 Doors And Hatches On Escape Routes

In addition to the requirements listed under Section 5.3, doors installed on egress routes shall also meet the following requirements [2]:

1. Doors installed on egress routes shall open in the direction of personnel movement in an

emergency. Sliding doors and hatches shall not be used for primary exits.

2. Emergency doors and hatches shall pose no safety hazard to personnel, either of

themselves or by their operation, and shall be as follows:

a. Easy to operate.

b. Directly accessible.

c. Unobstructed.

d. Easy to locate and operate in the dark.

e. Quick opening (3 seconds or less).

f. Opened using a force of between 10 lbf and 30 lbf (44 N and 133 N).

g. Be clearly marked on both sides of the door, hatch, or panel.

3. The “Open” action for doors and hatch handles shall be indicated.

4. Airlock doors shall be provided with a local alarm if pressurization is lost for 1 minutes.

5. Wherever possible, vertical hatches shall be able to be opened with one hand. Where this is not practicable, the weight of the hatch cover shall be minimized. Maximum weights for vertical escape hatch covers shall be as follows:

a. One-hand opening: Less than 14.3 lb (6.5 kg)

b. Stooping: Less than 14.3 lb (6.5 kg)

c. Standing, squatting, or kneeling: Less than 35.2 lb (16 kg)

6. The required dimensions of hatches are given in Figure 5.2 and Table 5.1 Hatches

Minimum Dimensions.

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Figure 5.2 : Hatches Minimum Dimensions

Table 5.1 : Hatches Minimum Dimensions

Hatch Shape Side Rectangle Square Circular

Top Entry

Side Entry

A

B

A

B

33cm

61cm

66cm

76cm

58cm

71cm

79cm

81cm

5.5 Walkways and Working Platforms

Platform within the scope facilities shall meet the following requirements [2]:

1. Platforms should be provided as indicated in Table 5.2 unless the equipment or facilities described are accessible from grade. Access to these platforms shall be by permanently installed ladders or stairs.

Table 5.2 : Equipment Platform Requirement

EQUIPMENT

SPECIFIC REQUIREMENTS

Service and Inspection Openings

Blanking/Isolation Points on Vessel Nozzles (including exchangers, filters, horizontal vessels, towers, and tanks)

Instrumentation and Controls, including Associated Manifolds and Takeoff Connections

All of which are located with the bottom of the opening more than 10 ft (3 m) above grade.

All of which are located with the bottom of the opening more than 10 ft (3 m) above grade.

1. All of which require Operator attention or that are otherwise observed, adjusted, or serviced during plant operation 11 times per year or more.

2. Access to instrument takeoff valves with

diameter less than 2 in. (50 mm) by permanent ladder with cage is acceptable.

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EQUIPMENT

SPECIFIC REQUIREMENTS

Control Valves, Pressure Relief Devices, Motor Actuated Valves (electric, pneumatic, or hydraulic operated), and Lubricated Valves

For those not located at grade elevation.

Emergency Block Valves (EBVs)

1. For those not located at grade elevation.

Other Operating Valves and Sample Outlet Valves

Machinery

Vertical Shell and Tube Exchangers

2. Permanent stair shall be provided, as required,

for direct access from grade.

Valves should be placed so that they can be safely operated from permanent platforms or grade.

For all machinery mounted on elevated

foundations or not otherwise accessible for operation and maintenance from grade or floor level.

Floor grating shall be provided between adjacent

cylinders of multi-cylinder compressors.

To access a component of the machine that may

not be accessible from grade (e.g., lube oil skid or seal pots).

To access enclosures or dampers on stacks.

For maintenance access to covers, channels, or bonnets, where the flanges of such components are more than 12 ft (3.7 m) above grade.

Separators, Basins or Tanks

Filter Housings

For operation of sluice gates, plugs, or similar control components.

Provide access for filter replacement.

2. Platform size shall be governed by the following:

a. Minimum unobstructed platform width shall be 30 in. (760 mm), except for the

services listed in Table 5.3.

b. Clear length and width of platforms dedicated to special operation and maintenance instrument maintenance, blanking of tower nozzle connections, removal and testing of pressure relief devices, and servicing corrosion probes or retractable water sprays.)

tasks shall be specified.

include

(Such

tasks

c. The space on platforms used for permanent or temporary storage of containers of catalyst, chemicals, and similar materials shall be specified and reserved in the layout.

d. Platforms around compressors, pumps, and other large machinery shall provide space for placement of rotors, impellers, similar components based on the vendor recommendations for maintenance. This shall be specified and reserved in the layout accordingly.

e. When welding terminal boxes are located on platforms in process unit structures, space shall be available on the platform (served by the welding box) sufficient to accommodate one welding machine.

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f. Guardrails shall have removable sections where specified for equipment maintenance. The sections of removable rails shall weigh less than 51 lb (23 kg) and be removable without the assistance of cranes.

Table 5.3: Minimum Clear Platform Widths

MINIMUM CLEAR WIDTH

SERVICE/LOCATION

In front of equipment for servicing trays

At each end of the shell and tube units for servicing bonnet, channel, and tube bundle

Connecting walkways between platforms or around elevated machinery

Around safety valves for maintenance

in.

36

36

30

42

mm

900

900

760

1,050

3. Platforms servicing equipment manways shall be not more than 42 in. (1,050 mm) below

the manhole centerline.

4. The minimum headroom over platforms and walkways that are not part of escape paths shall be 81 in. (2,050 mm). Headroom shall be measured to the lowest point of overhead structural insulation), or other obstructions.

fireproofing), piping (including

framing (including

5. Platforms for structures located within a 40 ft (12 m) horizontal radius of high fire potential equipment, or located above equipment handling flammable gases above their auto- ignition temperature or above 600°F (316°C), whichever is lower, shall be as follows:

a. Steel structures and equipment platforms: Floor plate

b. All compressor platforms: Grating

6. The use of a rolling stair/platform (in lieu of permanent structures) for access to equipment

near grade shall be approved by Company’s Engineer.

7. Areas designated for either equipment laydown or storage shall be clearly marked so that it can be seen both on the platform and on approach routes, indicating their maximum loading capacity.

8. The final number and arrangement of platforms, including access and exit locations, shall

be reviewed by Company’s Engineer.

9. Platforms attached to vessels or similar equipment shall be designed to accommodate

thermal expansion.

10. There shall be no gap greater than 1/2 in. (13 mm) between working/walking surfaces. This includes transitions between stair tower and deck/platform and distance between toe plate and edge of grating [2]. The gap between two adjacent sections of handrail shall not exceed 152mm (6in) [36].

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5.6 Stairs, Ladders And Ramps

5.6.1 General

1. Stairs, stair ladders, ramps, or ladders shall be provided for access to equipment in the facility to avoid having to climb on the actual equipment and pipework. Factors to consider are the type, direction, and frequency of traffic, clearance required, and applied loading [2].

2. Stairs and ladders to a platform shall not terminate in front of a vessel manway [2].

3. Ladders or stairways that provide egress from platforms or structures over a fire hazardous area, with containment shall be designed with the ladders/stairways exiting to a location outside the containment [2].

5.6.2 Stairs

1. Stair dimensions shall be in accordance with Figure 5.3. Stairways shall have a maximum vertical continuous flight of 12 ft (3.7 m) between landings and shall be constructed of steel. Landings shall be provided at every floor and shall have a level transition from the first and last treads to the working/walking surfaces [2].

2. Treads shall be open unless screens or kick plates are required to protect personnel or

equipment under the stairs [2].

3. Tubular pipe section shall be used for hand rails. Handrails shall be galvanized and

painted in accordance with Project Design Specification [2].

4. Stairs, not ladders, shall be provided for the following [2]:

a. Where equipment must be accessed or personnel evacuated during emergencies (e.g., battery limit valves, Shutdown Valves [SDVs], Emergency Shutdown Valves [ESDVs], and Blowdown Valves [BDVs]).

b. Where equipment is frequently accessed (i.e., at least once per shift on average).

c.

In areas where personnel are required to wear breathing apparatus.

d. Where personnel are required to carry tools, pieces of equipment, or sampling equipment. If load will exceed 29 lb (13 kg) or is bulky, then ramps or elevators shall be used as a means of ascent or the load shall be lifted using a crane or hoist.

e. For main operating levels.

f. For main service levels.

5. Stair ladders shall not be used. Stair ladders are defined as having as an angle of 50-75

degrees [2].

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Figure 5.3 : Required Stair Dimensions

Table 5.4 : Required Stair Dimensions

FEATURE

REQUIRED DIMENSIONS

in.

mm

A Tread Depth (Including Nosing)

11–12

280–300

B Riser Height

C Depth of Nosing (Where Applicable)

D Width (Handrail to Handrail)

Single person travel stairs

Simultaneous two-way travel stairs

E Overhead Clearance

7–8

1

36

48

84

180–200

25

915

1,220

2,130

F Height of Handrail (from leading edge of

34–38

865–1065

tread)

G Handrail Diameter (Round)

H Minimum Rail Clearance from Wall

I Angle of Stairs

Recommended

Acceptable Range

11/2–2

21/4

38–50

57

38 degrees

30–50 degrees

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5.6.3 Fixed Ladders

1. Ladders, railings, toe plates, safety cages, and similar items shall be constructed of steel per ASSE A1264.1 [34] and ALI A14.3 [35], except as modified below. Ladders are defined as having a pitch from 75 and 90 degrees. The following requirements shall be met:

a. Ladders shall be provided with for side-step access to platforms. Step-through ladders are not permitted for access to platforms [2]. This is applicable for access ladder on the platform. The ladder embedded inside a vessel or equipment for maintenance purpose can be referred to Figure 5.9 [36].

b. Generally, ladders shall be maximum 30 ft (9.1 m) unbroken length, landing-to- landing. For accessing flare platform, ladders shall be maximum 6.0 m to mitigate personnel fatigue. Fall arrest systems are required for ladders greater than 24 ft (7.3 m) from lower level [2].

c. Any inclined ladder shall have constant pitch from landing to landing. The required

pitch on fixed ladders shall be 90 degrees [2].

d. Safety cages shall be provided for ladders having a length of climb greater than 20 ft (6.1 m) or where the top platform is greater than 20 ft (6.1 m) above grade [2].

e. Where safety cages are required for ladders on elevated platforms and the ladder centerline is within 3 ft (0.9 m) from the platform side top rail or 4 ft (1.2 m) from the top rail on the climbing side of the ladder, the vertical cage bars shall be extended and attached to the guardrail top rail [2].

f. Ladder safety devices shall not be used in lieu of cage protection [2].

g. A single hoop (similar to the top hoop of a cage) shall be provided for ladders having a length of climb between 3 ft, 6 in. (1.1 m) and 20 ft (6.1 m) or where the upper platform is between 3 ft, 6 in. (1.1 m) and 20 ft (6.1 m) above grade for elevated ladders. The single hoop shall be located in line with the top rail of the platform guardrail [2].

h. Safety gates shall be self-closing, double-bar swing gates. The double bars of the safety gate shall generally align with the top and intermediate rails. The double bars shall be provided across ladder openings at each platform landing and designed for the same load as the railings. The safety gate hinge may be located either on the same side or opposite the ladder, as required for ease of use i.e. for the side step ladder safety gates, the hinge should be located the furthest away from the ladder and the door knob/handle should be located at the closest way from the body to create an ease use of opening the gate during climbing [2].

i. The minimum distance between ladders arriving and departing from a platform is 760mm (as per access area for working space and secondary escape route requirement) [2].

2. Ladders shall not be used where personnel are required to wear breathing apparatus [2].

3. Figure 5.4 to Figure 5.8 provide ladder and platform details. Tubular pipe section shall be used for handrails. Pipe dimensions shall conform to Figure 5.3 & Table 5.4 and its feature “G”. All handrails, kick plates and fittings shall be hot dipped galvanized after fabrication and then painted. Gas holes shall be drilled on the underside of pipe sections prior to hot dip galvanizing and sealed afterwards with plastic plugs [2].

4. Maximum reach to the side from a fixed ladder shall not exceed 48 in. (1,220 mm) as measured from the extended fingertips to the far side (or opposite side stringer) of the ladder [2].

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5. Safety gates shall be provided across ladder openings at each platform landing and shall be designed for the same load as the railings. Self-closing safety gate shall be installed in such that the three point contact (hands and foot) is maintained while opening the safety gate [2].

6. Safety gates shall be a minimum of 24 in. (610 mm) wide. A width of 30 in. (760 mm) is

preferred [2].

7. A self-closing safety gate shall be installed at the top of each ladder [2].

8. Safety gates shall open/close in the horizontal direction, be self-closing double bar type

and cover the full width of the opening between the ladder stringers [2].

9. The top bar of the safety gate shall be at the same height as the top rail of the guardrail

[2].

10. Safety gates shall be able to resist the weight of a 91 kg (200 lb) person in both the vertical

and horizontal direction [2].

11. The safety gate shall open away from the person climbing up the ladder [2].

12. A single metal bar that opens vertically or chains, wire rope, or other non-rigid barriers,

shall not be used [2].

13. Safety gates and associated toe plates shall be visually distinct from their surroundings.

The minimum toe plate height shall be 76mm [2].

14. Safety gates should be yellow in color and incorporate any required signage and markings

as dictated by local operating requirements [2].

Table 5.5: Typical Ladder Detail

REQUIRED SPACING

DIMENSION

Climbing clearance width (Figure 5.6)

Climbing depth in back of ladder (Figure 5.6)

Clearance depth on climbing side (Figure 5.6)

Height of stringer above landing (Figure 5.4)

Flare at bottom of cage (Figure 5.4)

Depth of cage from center of ladder (Figure 5.4)

Max distance between cage ribs (Figure 5.4)

Width of cage (Figure 5.4)

Maximum distance from ladder string to platform edge (side step ladder)

in.

30

7

30

48

32

28

18

27

6

mm

760

175

760

1,220

815

710

460

685

150

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Figure 5.4 : Typical Ladder Detail (Side-Step Access)

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Figure 5.5 : Ladder Cage Bar Extensions at Elevated Platform

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Figure 5.6 : Minimum Clearance to Obstructions

Figure 5.7 : Typical Guardrail Detail

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Figure 5.8 : Safety Gate Details

Figure 5.9 Ladder Inside Equipment Detail

Table 5.6: Ladder Inside Equipment Detail

Dimension

A Rung Thickness B Rung Spacing C Height, rung to landing D width between stringer E Climbing clearance width Clearance depth: F In back of ladder G On climbing side (range) height of stringer above landing

H

J height from lower elevation to

bottom rung

Recommended (mm) 32-38 230-380 150-380 300-530

610-760

150-200 760

910-1067

380

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5.6.4 Ramps

1. Ramp dimensions shall be in accordance with Figure 5.10 [2].

Figure 5.10 : Ramp Dimensions

Table 5.7: Ramp Dimensions

FEATURE

A Material Handling Angle of Rise

Personnel Traffic Angle of Rise

B Distance between Cleats

C Height of Handrail

D Width:

Minimum on Exit Routes

Minimum for Equipment Access

Minimum for Material Handling (determined by function and usage, particularly size of rolling stock and loads)

DIMENSIONS

in.

mm

0–7 degrees

0–15 degrees

14

42

44

30

48

355

865–1065

1,120

760

1,220

E Handrail Diameter (round)

F Clearance around Handrail

11/2–2

38–50

4

100

1. Ramps with slopes greater than 10 degrees shall be provided with cleats [2].

2. Ramps shall be prevented from extending further than 30 ft (9.1 m) by inserting a flat platform level. Flat platforms shall be provided at the bottom of the ramp and at any point at which the ramp system changes direction. See Figure 5.10 [2].

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Figure 5.11 : Ramp Design

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5.7 Workspace And Access

5.7.1 Workspace

1. Adequate workspace shall be provided for the use and placement of tools and for placing spare parts and components of equipment their repair/replacement. To establish workspace requirements, the following shall be considered [2]:

the work area during

in

a. Number of personnel required to do the work.

b. Equipment requirements (including maintenance instructions, check sheets, log

books, and other documentation that may be referred to).

c. Body positions that the personnel may need to adopt.

2. Platforms servicing large automated valves shall be sufficiently wide to allow moving the valves to and from the location. An allowance of 4 in. (102 mm) is required on either side of equipment or trolley [2].

3. At least 20 in. (508 mm) of clear space shall be provided around all removable spools

used for access and maintenance [2].

4. The type, size, and shape of access apertures chosen shall include consideration of the type of clothing and Personal Protective Equipment (PPE) that will be worn by personnel. Dimensions for typical work positions are presented in Figure 5.12 and Table 5.8 [2] .

5. The design of manways and other access/egress openings shall incorporate the following

in their design and positioning [2]:

a. Allow for the protective equipment (i.e., PPE, RPE, weather resistant clothing) that the operator will be required to wear under normal and emergency operating conditions.

b. The carriage of tools, equipment and materials

c. Anthropometrics of the personnel population

d. Emergency rescue requirements

e. Whether entry will be horizontal or vertical

f. Frequency of access

g. Task requirement – sufficient clearance for installing or removing vessel internals.

6. For offshore facilities, permanent access platform shall be provided should manway center

line height reaching 3 m and above [2].

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Figure 5.12 : Workspace Minimum Dimensions

Table 5.8 : Workspace Minimum Dimensions

TROPICAL / TEMPERATE ENVIRONMENT (2) (3)

WORKSPACE AREA

Standing and Moving Workspace

A.

B.

Height

Width

Vertical Entry Hatch

C.

Square

Horizontal Entry Hatch

(4)

D1.

D2.

Shoulder Width

Height

Squatting/Kneeling Workspace

(1) (2)

E.

F.

G.

Crawling Space

Height

Depth

Depth

(1) (2)

in.

81

28

24

24

24

48

36

40

mm

2,050

760

610

610

610

1,220

910

1,020

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WORKSPACE AREA

H.

I.

Notes:

Height

Length

TROPICAL / TEMPERATE ENVIRONMENT (2) (3)

in.

36

70

mm

910

1760

(1) Use dimension B shoulder width for workspace width. (2) These dimensions do not allow for any breathing apparatus to be worn. To allow for breathing equipment such as an air pack, add an allowance of 11 in. (280 mm). Ladder cages cannot be increased in diameter and normal access shall be by stairs when using SCBA.

(3) Tropical/Temperate Environment assumes normal process work clothing. Arctic Clothing assumes parka, insulated work pants, arctic work boots, and gloves/mittens.

7. Vertical access dimensions for reaching and gripping an item from underneath are as

follows (this does not include applying a force; e.g., closing a valve) [2]:

a. Maximum overhead grip reach (standing) = 72 in. (1,829 mm)

b. Maximum overhead grip reach (kneeling) = 51 in. (1,295 mm)

c. Maximum overhead grip reach (lying in face-up position) = 22.5 in. (572 mm)

8. Adequate spacing around components (e.g., bolts, electrical connectors, etc.) shall be provided to take into account the need for personnel to wear gloves or use tools [2].

The following dimensions are recommended [2]:

a. Pushbutton access:

i. Bare Hand: 1.25 in. (32 mm) diameter

ii. Gloved Hand: 1.5 in. (38 mm) diameter

b. Two-finger twist access:

i. Bare Hand: Object diameter plus 2 in. (50 mm)

ii. Gloved Hand: Object diameter plus 2.5 in. (65 mm)

iii. Mittened Hand: Object diameter plus 3 in. (76 mm)

9. Recommended minimum dimensions for arm and hand access are provided in Table 5.9

and Table 5.10 [2] .

10. Recommended designs of aperture covers are provided Table 5.11 [2] .

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Table 5.9 : Minimum Aperture Dimensions for Arm Access

TYPE OF ACCESS

CLOTHING

ACCESS DIMENSIONS

Reaching Full Arm’s Length (to shoulders) with Both Arms

Light clothing

Width: 19.5 in. (495 mm)

Height: 5 in. (127 mm)

Arm to Elbow

Light clothing

4.3 in. x 4.7 in. (109 mm x 119 mm) or 5.5 in. (140 mm) diameter

Arm to Shoulder

Light clothing

6.0 in. (152 mm) square or diameter

Table 5.10 : Access Opening Dimensions

TYPE OF ACTION

ACCESS DIMENSIONS

Using a common screwdriver with freedom to turn the hand through 180 degrees

Using pliers and similar tools that require gripping

Using a T-handle wrench with freedom to turn the tool and hand 180 degrees

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TYPE OF ACTION

ACCESS DIMENSIONS

Using an open-end or box-end wrench with freedom to turn the wrench through at least 60 degrees

Grasping and manipulating small objects (up to 21/4 in. [57 mm] wide) with one hand

Grasping large objects with one hand

Grasping large objects with two hands, with the hands extended through the opening up to the length of the fingers

Grasping large objects with two hands, with the arms extended through the opening

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Table 5.11 : Access Aperture Covers

COVER DESIGN

COMMENTS

Best: No cover Use whenever possible.

Permanent glass or plastic cover Use where only visual inspection is required.

Hinged or sliding cover Use where physical access is required and where dirt and moisture could be a problem.

Captive quick-opening fasteners Use when space prevents use of hinged cover.

Screwed-down cover Use only when stress or pressurization requires; use minimal number of screws.

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5.7.2 Deck Surfaces : Slip and Trip Hazards

1. Deck surfaces shall have a nonslip finish or surface coating that will maintain its nonslip properties in the environmental conditions to which it is exposed (e.g., rain, sea water, icing, high temperatures, etc.) [2].

2. Decks shall have camber and drainage points to remove liquids [2].

3. Where there are steps, clear indication of the change in elevation (e.g., alternate black and yellow stripes painted on the edge of the steps) shall be provided on at least the first step ascending/descending and last step ascending/descending. The proportion of the brighter color (e.g., yellow) shall be at least 50% of the warning area [2].

5.7.3 Access

1. Table 5.12 provides the minimum maintenance access spacing - for Operators and for the use of tools - to line flanges and valve bonnets. Table 5.12 is not applicable to lines in pipe racks [2].

2. Where possible, equipment shall be positioned within the horizontal reach distance

specified in Table 5.13, without the need for leaning onto equipment [2].

Table 5.12 : Access Spacing to Line Flanges and Valve Bonnets

NO. NOMINAL LINE DIAMETER MINIMUM SPACING (OUTSIDE OF FLANGE

2 in. (50 mm)

3–4 in. (75–100 mm)

6–8 in. (150–200 mm)

10–20 in. (250–500 mm)

TO NEAREST OBSTRUCTION)

Maintain 28 in. (710mm) one side (from the Front) which will be main means of access, other side 16 in. (150mm) to any obstruction.

Maintain 28 in. (710mm) one side (from the Front) which will be main means of access, other side 8 in. (200mm) to any obstruction.

Maintain 28 in. (710mm) one side (from the Front) which will be main means of access, other side 14 in. (350mm) to any obstruction.

Maintain 28 in. (710mm) one side (from the Front) which will be main means of access, other side 18 in. (450mm) to any obstruction.

24 in. (600 mm)

Maintain 28 in. (710mm) both sides.

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Table 5.13 : Horizontal Reach Dimensions

TYPE OF REACH (“A”)

MAXIMUM ALLOWABLE REACH

Standing lateral reach (preferred arm)

Maximum depth of reach = 21.8 in. (550 mm)

Standing forward reach (two arms)

Maximum depth of reach = 17.5 in. (445 mm)

Standing forward reach (preferred arm)

Maximum depth of reach = 19.5 in. (495 mm)

Seated forward reach (both arms)

Maximum depth of reach = 14.0 in. (360 mm)

Cross legged seated forward reach (both arms)

Maximum depth of reach = 13.5 in. (340 mm)

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5.8 Valves

5.8.1 General

1. Manual operation of valve hand wheels, manual gear operators, or levers shall not require application of force exceeding 50 lb (22.7 kg). Operating valves that require a greater force to turn shall be motor-operated [2].

2. Frequently operated valves (frequency greater or equal to once per week) requiring more than 40 turns from open to close shall be motor-operated. Valves with lower operation frequency shall have an attachment to accommodate a portable valve actuator [2].

3. Valves shall be selected and installed to ensure the consistent operating convention of increasing flow when the actuator is turned counter-clockwise or is moved to be parallel (in- line) with the valve body [2].

4. Hand wheels of less than 4 in. (100 mm) in diameter should be provided when intended for one-hand operation. Hand wheels of greater than 6 in. (150 mm) in diameter should be provided when intended for two-hand operation. Hand wheels with diameters between 4 in. (100 mm) and 6 in. (150 mm) should not be used [2].

5. Minimum clearance shall be 3 in. (76 mm) between adjacent valve hand wheels and equipment or structures and 2 in. (50 mm) between the back of the hand wheel and insulation on the line [2].

6. Use of valve wrenches shall require approval by Company’s Engineer. Additional clearance

shall be provided for wrench-assisted operation of valve hand wheels [2].

7. Valve handles shall be oriented such that they do not turn to restrict the access or walk-

through pathway in front of the valve [2].

5.8.2 Manual Valve Categories

Category 1 Manual Valve

1. Category 1 (C1) manual valves are those essential to normal or emergency operations where rapid and unencumbered access and operation or maintenance is essential. Valves meeting any of the following shall be qualified as Category 1 manual valves [2]:

d. Essential valves for operations

e. Equipment isolation valves

f. Essential valves for personnel or process safety and for pollution prevention.

g. Valves where there is a high likelihood of maintenance (e.g., control valve and

corrosive/erosive service).

h. Valves where the lack of quick access would result in damage to personnel or property,

loss of productivity, or damage to equipment or the environment.

i. Valves where an expected operational and/or maintenance frequency is greater than

once in a 6 month period.

2. Examples of valves typically included in Category 1 are as follows [2]:

j. Control valves, bypasses, and isolation valves

k.

Isolation valves for pumps, compressors, filters

l. Throttling valves

m. Battery limit valves

n. Valves associated with sampling facilities for gas and liquid

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o. Valves associated with periodic and frequent purging e.g. flare header end.

p. PSV and associated vent valves without a PSV spare line

Category 2 Manual Valves

1. Category 2 (C2) manual valves are those that are not critical for normal or emergency operation or maintenance but are used during routine maintenance activities. Portable platform may be used but shall be approved by Company’s Engineer [2].

2. Examples of valves typically included in Category 2 are as follows [2]:

a. Sewage treatment valves

b. Drain/vent valves

c. Manual valves with an expected operating and/or maintenance frequency of less than

once per 6 months

d. Valves where quick action is not required

e. Valves associated with level gauge (LG) and level transmitter (LT)

f. Valves associated with temperature instruments (TI)

g. Valves associated with purge and flushing connection

h. PSV and associated vent valves with a PSV spare line

Category 3 Manual Valves

1. Category 3 (C3) manual valves are those used in particular circumstances on an infrequent

or rare basis [2].

2. Examples of valves typically included in Category 3 are as follows [2]:

a. Valves used in initial commissioning

b. Valves used for decommissioning

c. Valves used during turnarounds

d. Utility header isolation valves

e. Buried or pit-located valves

Manual Valve Placement

1. C1 and C2 valve hand wheels shall be located as shown in Figure 5.13 and Figure 5.14 as

follows [2]:

Category 1 a. C1 manual valves shall not be fitted outside the indicated locations.

b. For large C1 actuated valves e.g. SDV and MOV, access to panels, actuator limit switches, and handwheels could be by a portable platform. The portable platform shall be equipped with proper steps and lockable wheels.

Category 2 c. C2 manual valves shall be located in either Category 1 or Category 2 valve locations.

d. Access platform with vertical ladder should be provided where the C2 valves need to be

operated and maintained.

2. C3 manual valve hand wheels should be located as shown in Figure 5.13 and Figure 5.14.

3. An 18 in. (460 mm) radial clear space shall be provided around valve bonnets.

4. It should be possible to visually determine valve position from normal platforms and

walkways.

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Figure 5.13 : Recommended Mounting Heights for Horizontal Valve Hand Wheels

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Figure 5.14 : Recommended Mounting Heights for Vertical Valve Wheels

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6 WORKING ENVIRONMENT

This Section identifies the minimum requirements for a working environment to ensure the comfort of and to enhance the effectiveness of operating and maintenance staff.

6.1 Lighting

Lighting shall be provided in accordance with Lighting Design Philosophy [23]. Additionally, following requirements shall be considered:

1. Supplement general lighting systems with local special-purpose lighting for difficult

inspection, repair, and document-reading tasks.

2. Locate lights for recessed displays, or panels with access doors to ensure that recessed

displays are illuminated.

3. Minimize the potential for self-reflection by careful orientation of displays with respect to

the observer.

4. Avoid optical distortion from glass cover plates by using flat glass covers rather than dome

glass covers.

5. Cover large surface areas with non-saturated colors such as tints, pastels, and warm grays

that are non-glossy.

6. Minimize glare and reflections through the design approaches provided in below Table.

Table 6.1 : Measures to Control Direct and Indirect Glare

DIRECT GLARE

INDIRECT GLARE (VEILING REFLECTIONS AND REFLECTED GLARE)

1. Position light sources and lighting

2. Use light sources with diffusing or

units as far from the person’s line of sight as possible.

polarizing lenses.

2. Use surfaces that diffuse light such as

3. Use several low-intensity light

sources instead of one bright one.

flat paint, non-gloss paper, and textured surfaces.

3. Use light sources with louvers or

4. Change the orientation of a

prismatic lenses. 4. Use indirect lighting. 5. Use light shields, hoods, and visors at the workplace if other methods are impractical.

workplace, task, viewing angle, or viewing direction until maximum visibility is achieved.

4. Eliminate extreme glare hazards such as brightly polished bezels, glossy enamel finishes, and highly reflective covers.

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6.2 Thermal Environment

6.2.1 Temperature

1. Exposure to thermal stress (cold and heat) shall be considered in the design philosophies and the design of the facility. Facility designs shall provide for thermal exposure protection and recovery [2].

2. Where Heating, Ventilation, and Air Conditioning (HVAC) is to be provided, temperature, humidity, and ventilation shall be controlled in in accordance with Technical Specification HVAC Systems [2].

3. Where equipment is expected to require maintenance in cold weather, the

following design features should be considered:

2. The effects of rain (e.g., drainage), shall be considered when locating access doors

and panels.

3. Workspace access openings shall be provided to accommodate personnel wearing

breathing apparatus [2].

4. During outdoor work, strong winds pose particular problems for work at heights, manual handling, and maintenance work; therefore, wind trap and downdraft checks shall be performed. Placement of equipment that will need a high level of human interaction shall be avoided in these positions, or provisions for temporary or permanent windbreaks, shielding walls, and shelters (especially against wind chill) shall be provided [2].

5. Personnel protection shall be provided for surfaces that will operate above 60 °C and that are located within 0.3 m horizontally and 2 m vertically above a normal walkway or working area. Refer to Thermal Insulation Specification [24].

6.3 Vibration

6.3.1 Whole Body Vibration

Exposure to whole body vibration shall be controlled, and measures shall be taken to limit personnel exposure to whole body vibration as per ISO 2631 [41].

6.3.2 Hand-Arm Vibration

Exposure to hand-arm vibration shall be controlled, and measures shall be taken to limit personnel exposure to hand-arm vibration as per BSI BS EN ISO 5349-1 [39].

6.4 Noise Reduction And Control

Noise levels shall be controlled in accordance with the Noise and Vibration Design Philosophy [15] for this project.

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7 EQUIPMENT

The layout of auxiliary equipment, valves, controls, and displays for parallel units (e.g., spared pumps) shall be identical in relation to the equipment controlled.

Layout of local control stations and local control panels for similar or identical equipment and trains shall be similar for each piece of equipment.

Valve stations with similar purposes shall have similar arrangement and appearance.

Where possible, equipment shall be specified to have a small number of large fasteners rather than a large number of small fasteners.

7.1 Generic HFE Requirement

Table 7.1 describes the generic HFE requirement for each type of equipment based on HFE Screening outcomes. These requirements should be incorporated in equipment design where applicable, and verified accordingly [2].

Table 7.1 : Generic HFE requirements for equipment

NO. EQUIPMENT

HFE REQUIREMENT

1

Centrifugal pump

i) Ensure the space for pump removal is not blocked by auxiliary

equipment.

ii) Provide sufficient headroom and surrounding space for pump lifting and material handling equipment maneuvering e.g. vertical can

iii) Ensure the vibration test point is accessible from deck or

access platform.

iv) Provide access for purging and cleaning of the pump

assembly.

v) Consider bearing replacement in design. vi) Accessibility to lube oil filter replacement (where provided) vii) Accessibility to mechanical seal and coupling repair /

replacement

2

Submersible pump

i) Allocate sufficient space at laydown and storage area for

placing pipe columns (7-10 columns) temporarily.

ii) Simplify the task by considering to lift two columns at one time (e.g. 6.0 m length) and provide sufficient length of storage area for the columns.

iii) Provide access for both sides of the engine (FWP). iv) Provide sufficient space and correct procedure for cable handling during pump removal i.e. provide dedicated equipment for cable management.

v) Handling of hypochlorite injection cable and pipe. vi) Verify the line of sight between crane cabin and pump lifting

area.

vii) Provide means of communication between crane cabin and

pump lifting area.

viii) Provide special tools (clamping devices) for removing the pipe

columns and pump/motor.

ix) The location of pump junction box shall not impede the

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NO. EQUIPMENT

HFE REQUIREMENT

maintenance area.

x) Hatch opening shall clear from obstruction e.g. piping, tubing,

cable tray.

xi) Consider to provide appropriate barrier to mitigate swing load

during pipe column lifting.

3

Filter / Coalescer

i) Provide sufficient clearance for the top flange opening and

personnel access around the vessel.

ii) Consider to provide access platform for the top flange (1100

mm height).

iii) Provide handling facilities for filter element weight of more

than 23 kg (each).

4

Tank / Vessel

i)

Identify the location of manway and accessibility into the tank. Sufficient space or access platform shall be provided if confined space entry (CSE) is anticipated i.e. involved breathing apparatus.

ii) Provide sufficient holding point and ladder rungs inside the

vessel for manway entry.

iii) Accessibility of sight glass and level gauges. iv) Accessibility of vent valve at the top of vessel. v) Accessibility of isolation points of instruments (as outlined in

Section 5.8)

vi) Accessibility and maintenance of vessel internals should be by

scaffolding, where applicable.

5

6

Caisson

Ensure the correct nozzle size for remote camera insertion and accessibility to the nozzle. Based on baroscopic inspection study.

Tote tank

i) Accessibility to tie-ins connection for frequent tote tank

change-out.

ii) Provide sufficient space for material handling of tote tanks iii) Provide sufficient space for access around the tote tanks. iv) Provide dissimilar nozzles to prevent cross-contamination

between different tote tanks / chemicals.

v) Provide vertical ladder on the tote tank lifting frame for

accessing top opening cover and instruments.

7

Shell and tube heat exchanger (STHE)

i) Major task will be tube bundles removal; provide sufficient

clearance for tube bundle removal area i.e. the bundle puller length, temporary supporting structure, and 1500 mm back clearance.

ii) Accessibility for inspection and calibration of level gauges,

level transmitters, and pressure transmitters (concern on accessibility of upper part of stacked vessels) if applicable.

iii) Accessibility of vent and drain valves.

8

Heater

i) Ensure full access to the main terminal box. ii) Accessibility of bleed point valves (within coaming area).

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NO. EQUIPMENT

HFE REQUIREMENT

9

Plate heat exchanger

i) Provide adequate space for plate removal. ii) Adequate space for scaffolding installation around the equipment for visual inspection of complete package.

iii) Provide a pulling device for removing the main frame, if

manual handling is not possible.

10 Gas Turbine

i) Consider to use vendor’s special tools and cradle for gas GG

Generator (GTG) & Export Compressor (GTC)

and PT removal.

ii) Accessibility of GTG generator cooler shall be provided. iii) Ensure the MH system for removing GG and PT is in-place

i.e. space clearance and structural interface design.

iv) GTG/GTC enclosure panels should be designed as removable

type where applicable, for major components removal. Alternatively, sufficient doors opening shall be considered for largest components removal.

v) Ensure a gearbox removal is not blocked by GTG/GTC

enclosure (where applicable).

vi) Dedicated stairs/stool shall be provided at all doors for

frequent access and inspection.

11 Pedestal Crane

i) Evaluate the requirement of escape from the crane cabin and

crane boom.

ii) Accessibility of sheaves for inspection and replacement. iii) Develop procedures to mitigate potential collision between two

cranes.

iv) Establish no go zone area (to mitigate dropped object risk). v)

Identify laydown area for the crane davit for motor maintenance.

vi) Provide sufficient space and appropriate method for winches

and wire ropes replacement.

vii) Allocate dedicated area for hook inspection.

i) Provide appropriate and temporary MHsystem for flare tips replacement. The MH system shall minimize the manual handling tasks. Intermediate landing for ladder climbing for flare tower should be maximum 6.0 m intervals to mitigate personnel fatigue. iii) Requirement of fall arrest for the ladder (90.0 m) e.g. cable or

ii)

track type, safety body harness.

viii) Accessibility of thermocouple inspection.

12

Flare tip

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7.2 Material Handling

Material Handling shall be done in compliance with the Material Handling Philosophy [19]. With respect to human factors, the following key points are highlighted:

1. All material and equipment movement within the platform will be achieved by combining the use of pedestal crane and / or permanently or temporarily installed material handling equipment.

2. The design of equipment shall be such that it can be subdivided into smaller subunits to

facilitate removal, repair, or replacement of the subunits.

3. The weights of all subunits and components shall be clearly documented in the information material supplied by Contractor with the equipment. Weight of equipment and lifting device capacity shall be verified prior to lifting.

4. As a general guideline, items (e.g. motors, pumps) weighing more than 23kg should be lifted or moved using a hoist or trolley. Items weighing less than 23kg could be manually handled. As far as practically possible, all components weighing more than 23kg, should be fitted with lifting point / method. All lifting point shall be third party certified and certificates shall be provided to Company.

5. Sufficient access to the equipment shall be provided so that one person in a neutral position can lift pieces of equipment weighing up to 51 lb (23 kg). For lifts up to 51 lb (23 kg) in a non-neutral position or for lifts greater than 51 lb (23 kg), sufficient access for two people or lifting assist equipment shall be provided. A mechanical lifting method for equipment weighing more than 51 lb (23 kg) shall be provided.

6. Lifting limits on hoists, monorails, davits, and beams shall be identified and clearly labelled.

7. Lifting zones and laydown areas shall be clearly identified by use of floor markings.

8. Hoists, permanent lifting equipment (such as lifting beams), or access by pedestal cranes shall be provided to remove automated valves, control valves, pressure safety valves, in- line instruments, and removable spools.

7.3 Large Equipment and Rotating Machinery

The following requirements are applied to gas turbines, gas compressor, electric generators, large motors, gears, and some pumps [2].

1. If practical, pumps (typically reciprocating pumps, gear pumps, chemical injection pumps, etc.) should be positioned on a raised platform with access from all sides to avoid having to maintain the pump while crouching at floor level.

2. Access covers shall be labelled to advise personnel of any hazards beyond them.

3. Associated pressure gauges shall be visible from the work position required to open up

the pump or access the lubrication and test points.

4. Adequate space based on the minimum volumes for standing, or squatting/kneeling positions shall be provided around pump and compressor seals, couplings, bearings and stuffing boxes for removal and replacement activities.

5. Guards shall be provided around all exposed rotating equipment, as well as other moving or potentially hazardous points of contact (e.g., hot or cold surfaces, exposed electrical wiring, and crushing points). Quick fasteners shall not be used. Guards shall be accessible from at least two sides (i.e., a guard over a rotating shaft accessible from either side of the shaft).

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6. Sufficient space provision shall be provided for item retrieval i.e.: Compressor bundle, pump rotor, alternator. Sufficient lifting points i.e.: pad eye / monorails to assist the removal shall also be provided.

7.3.1 Local Displays and Controls

1. Equipment Emergency Shutdown (ESD) buttons shall be placed in a visible location, close to the main work position, and shall be suitably color-coded and guarded from inadvertent operation. Signage in an elevated position above location of ESD/manual call points shall have signage visible along access/escape routes where ever possible [2].

2. Additional manual call points next to each exit route out of the compressor housing/enclosure shall be separated with ESD buttons to avoid inadvertent operation of wrong button [2].

3. Local instruments associated with the equipment shall be located in accordance with

Section 7.1 of this specification.

4. If the compressor is housed or enclosed, then instrumentation / associated equipment requiring frequent monitoring or inspection while the compressor is running shall be located outside the compressor housing or enclosure (if possible). The displays shall be large enough and positioned to be viewable from outside the housing or enclosure (this would also require suitable and sufficient window access and lighting) or shall be positioned/relayed outside the housing or enclosure [2].

7.4 Overside And Suspended Work

1. The need for over side or suspended maintenance and access shall be minimized by one

or more of the following [2]:

a. Positioning equipment so that it can be accessed from the normal deck area

b. Providing an access way (for work sites that are frequently accessed or where the

task would be problematic from roped access)

c. Designing equipment that can be easily hoisted from its position to a deck area

2. Attachment points shall be located so that safety lines can be arranged in such a way that

the maximum potential fall shall be no greater than 80 in. (2,032 mm) [2].

3. The location of the attachment points above deck, or the path of the ropes from the

attachment points to over the side, shall not obstruct escape routes [2].

4. Where possible, a platform (either permanent or temporary) shall be provided at the work

site to avoid suspended working [2].

7.5 Local Instruments

7.5.1 Moving To and Workspace Around the Local Instruments Locations

1. Access to and workspace around the local instrument locations shall be provided in

accordance with Section 5 of this specification [2].

2. Clearance shall be provided both above and below control valves and shall be sufficient

to include access by mobile equipment in order to facilitate maintenance tasks [2].

3. Adequate clearance and access to enable rodding of instrument taps shall be provided

[2].

4. Instruments shall be located so that they are visible from the normal work position without needing to stand on other items of equipment, components, pipework, cable trays, handrails, etc [2].

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7.5.2 Displays and Controls

1. Important displays (i.e., those requiring precise, frequent, or emergency use) shall be located in a primary viewing area per Figure 9.5 of this specification and at a height of between 40 in. (1,015 mm) and 70 in. (1,780 mm) above the standing surface [2].

2. Instruments located in vibration areas shall have a high luminance for displays to thus

increase contrast and shall have an increased thickness of displayed numbers [2].

7.6 Pipework And Valves

7.6.1 Controls and Displays

1. Manually operated valves and associated local displays shall be placed so that Operator

can view the affected equipment and monitor the result of control actions [2].

2. For manual operation of valves, there shall be adequate feedback to Operator confirming that the valve has been activated and indicating the current valve status (fully closed, fully open, or partially open) [2].

7.6.2 Spacing

1. Distance requirements specifically for pipe (with / without insultation) to pipe (with / without insulation) and nearby structural supports should be maintained as per project piping design basis and specification [2].

2. The distance between piping shall allow for the turning of any spectacle blind, bolting,

unbolting and torquing activities, if present [2].

7.7 Test And Valves

1. Sample point valves are considered Category 1 manual valves [2].

2. Test points and sample points shall be readily accessible. Test points should be positioned on or behind equipment access points that may be easily reached or readily operated when the equipment is fully assembled and installed [2].

3. Sample points shall be identified with a permanent, corrosion-resistant tag that is securely fastened (adhesive fastening is not acceptable) [2]. Each tag shall include the following information [2]:

a. Unit name

b. Unit sample identification

c. Sample identification for accounting purposes

d. Physical state (liquid, vapor, or solid)

e. Temperature

f. Pressure

g. Warning signs, if toxic substances are present

4. Test and sample points shall be located away from dangerous electrical, mechanical, thermal, or other hazards. In addition to providing guards and shields 4.5 in. [115 mm] (a hand’s width) separation shall be provided from the nearest hazards [2].

5. Test and sample points shall be grouped logically in a line or matrix reflecting the sequence of tests to be made. Locating a single test or service point in an isolated position shall be avoided, as such points are the most likely to be overlooked or neglected [2].

6. Test and sample points and their associated labels shall be located so that they face the

user [2].

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7. Test points used for adjusting a unit shall be located close to the related controls and

displays [2].

8. Where items requiring frequent visual inspection (e.g., gauges, indicators, etc.) are located inside an enclosure, test points shall be designed with windows to provide immediate visual access [2].

9. If it is necessary to lubricate equipment, then greasing or filling points shall be grouped

together [2].

10. When pulling a hot liquid sample, an engineered barrier (such as a stand box and a clear cover plate) shall be provided so that Operator will be guarded from splashed hot liquids. Proper drainage facilities shall be provided the same [2].

7.8 Communication Systems

The Communication Systems on the CP6S and CP7S Compression Complexes are designed based on the following:

• Telecommunication System Philosophy for CP6S and CP7S Complexes [24]

• Specification for PAGA System for CP6S and CP7S Complexes [26]

• Telecom Design Basis [25]

The following subsections summaries the key human factors elements. For more information please refer to the above documents.

7.8.1 System Requirements

1. A sufficient number of communication channels to avoid excessive waiting for a free

channel shall be provided.

2. Dedicated lines shall be provided for frequent, lengthy, or emergency communications.

3. Portable communication systems shall be provided as needed to supplement installed

systems.

4. Where possible, Operators’ microphones, headphones, and telephone headsets shall

permit hands-free operation under normal working conditions.

5. Communication systems (e.g., telephones, radio units, etc.) shall be located so that the time and effort required for access by personnel is not excessive and so that stations are in areas of relative quiet.

6. Where communication requirements necessitate the use of several telephones and radio units, their locations should be determined by operational priority. Where Operators use several telephone and radio units, color coding of handsets to facilitate easy identification shall be considered.

7. Headphones and telephone headsets shall be designed for maximum Operator comfort.

No metal parts of the headset shall come in contact with the user’s skin.

8. Communications systems shall be designed to allow use by personnel wearing protective

clothing.

9. Dual communication systems and electricity and power supplies shall be provided to maintain communication during emergencies (e.g., bullhorns, battery backup, and separated cabling routes).

7.8.2 Speech Transmission and Reception Equipment

1. When selecting types of microphones, the following factors shall be considered:

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a. Single versus multiple inputs

b. The mobility of the user

c. Physical constraints on the user (e.g., hands not free to hold the microphone)

d. Ambient noise

e. Special user constraints (headgear, oxygen mask, etc.)

2. The dynamic range of a microphone used with a selected amplifier shall be great enough

to allow variations in signal input of at least 50 dBA.

3. If a console Operator’s hands are occupied so that Operator cannot pick up a microphone,

then a fixed microphone shall be located as close to Operator’s mouth as practical.

4. When the user is in an intense noise field, telephones shall be placed inside an Acoustic Hood. Acoustic Hood shall be designed to provide noise reduction or insulation up to 25 dBA.

5. Accessible volume or gain controls shall be provided for each communication- receiving

channel.

6. Where communication channels are to be continuously monitored, a means shall be provided to suppress channel noise during no-signal periods (e.g., squelch control).

7.8.3 Audibility and Recognition of Signals and Alarms

1. The number, location, and amplitudes of Public Address (PA) system loudspeakers shall be adequate to ensure the intelligibility of announcements throughout workspaces in all potential noise conditions.

2. When visual alarms are required in high noise equipment housings or enclosures,

loudspeaker coverage shall reach the area outside.

3. At a workstation where a single person uses a speaker, the speaker should be mounted

directly in front of the user and be equipped with a volume control.

4. Where audio alarms are intended to draw Operator’s attention to a warning, the alarm

signal shall be easily distinguished from routine signals and communications.

5. A message priority system shall be established so that critical automated messages

override the presentation of any other communications that are less important.

7.8.4 Evacuation Alarm Systems

1. Audible alarms, rather than visual alarms, shall be used to alert personnel to muster. Audible alarms shall be able to deliver at least 65 dBA and shall be adjustable to support an output level that is 6 dBA above any background noise not exceeding 120 dBA.

2. In accommodation modules, audible alarms shall be at least 85 dBA.

3. The alarm frequency shall be between 500 Hz and 3,000 Hz.

4. Audible alarms shall be designed to minimize the likelihood of startling personnel. In the first 0.2 seconds of the audible alarm abruptly rising waveforms, square-topped waveforms, and use of the maximum sound level shall be avoided. As general guidance, a startled reaction may be expected if the sound level rises by more than 30 dBA in 0.5 seconds.

5. The General Platform Alarm (GPA) and the Prepare to Abandon Alarm shall be distinct

from each other and from all other alarms.

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6. PA announcements shall be heard over the audible alarm. Announcements shall be at least 6 dBA above the audible alarm signal. The PA is allowed to temporary override the GA signal for this purpose.

7. The PA announcement shall not become distorted through reverberation or interference.

8. Visual alarms shall have a flash rate of between 60 to 180 flashes per minute (1 to 5 Hz or 1 to 5 FPS) with equal intervals of light and dark between the signals. The visual alarm light shall have at least a 10% greater luminance level than the surrounding area. Flash rates should not exceed 5 Hz (5 fps) and multiple flash sources should be synchronized to produce a combined flash rate no more than 5 Hz (5 fps).

9. Only a single flashing pattern shall be used for a visual alarm.

10. Visual alarms shall be placed away from bright light sources that may mask the signal.

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8 SIGNAGE AND EQUIPMENT LABELLING

This Section identify the minimum requirements for the design of signage and equipment labelling. Project shall determine if dual/multiple language signs are required. Signage and equipment labelling shall be meet the requirement of project specification [2].

8.1 Characters and Numerals

1. For non-emergency signs or signs in well-illuminated areas, the safe viewing distance—

defined by legibility limitations—should conform to Equation 1 listed below:

Where,

H = Height of the character

D = Safe viewing distance

𝐻𝐻 =

D 200

2. The character size on a display shall be at least 1/8 in. (3.175mm) for a viewing distance

that is less than 28 in. (710 mm).

8.2 Pipe Labelling

All piping systems in the facility shall be labeled in accordance with Panting Specification [28].

8.3 Electrical Wire And Cable Labels

All electrical wiring, cabling, and wire terminals in the facility shall be labeled in accordance with Technical Specification for Electrical Cable [29].

8.4 Hazard Signs

1. All hazard signs shall conform to NEMA Z535.1, NEMA Z535.2, and NEMA Z535.3 [43].

2. The terms “Danger” and “Caution” shall not be used as signal words except for hazard

signs per NEMA Z535.1, NEMA Z535.2, and NEMA Z535.3 [43].

Refer to Specification And Datasheets For Safety Signs [22].

8.5 Text, Wording And Symbol Use For Signs And Equipment Handling

1. Descriptive text should always be used in conjunction with accompanying international

symbols to further identify the issue.

2. Signs shall use short, simple sentences or phrases. If long phrases or sentences are required, then mixed-case lettering shall be aligned to the left margin (“left-aligned”) for languages that read from left to right. For languages that do not read from left to right, alignment shall be set to the standard reading starting position/direction for that particular language.

3. For signs containing operating procedures, the key information shall be provided in an

outline format.

4. For signs containing operating procedures, the full written manual shall be referenced to

provide additional detail.

5. Where necessary, the full written operating procedure shall be located at or near

equipment signs.

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6. Step-by-step procedures shall be numbered and left-aligned.

7. Use both human-readable text and symbols to convey the information in all regulatory

signs and labels.

8. Ensure that regulatory signs and labels comply with international and national standards

and codes.

9. Use black text on a white background for miscellaneous signs and labels.

10. Do not use the terms “Danger” and “Caution” as signal words.

11. Use mixed case and left justified text for long phrased and sentences in English. Format

Arabic phrases as appropriate.

12. Always use human-readable text with symbols.

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9 CONTROL ROOMS AND CONTROL PANELS

This Section identifies the minimum Human Factors requirements for the design of control rooms and control panels.

9.1 Visual Displays

9.1.1 Distance and Angles

1. Ergonomic design of control consoles shall be used to help reduce the likelihood of musculoskeletal disorders. The work surface height and the clearance under the work surface of a console shall meet requirements in ANSI/HFES 100 [42] or ISO 9241- 11 [40] or ASTM F 1166 [36].

2. For control panels at which Operator is normally standing, there shall be at least 28 in.

(710 mm) of free access space in front of the control panels.

3. The displays shall be mounted where each is easily viewed from Operator’s normal

working position per Figure 9.1 and Figure 9.2 .

Figure 9.1 : Vertical Viewing Angles

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Figure 9.2 : Vertical Viewing Angles

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Figure 9.3 : Horizontal Viewing Angles

4. Displays shall be located such that they are visible from normal work positions, without resorting to use of ladders and without requiring personnel to stand on equipment, components, or handrails. The minimum viewing distance from the observer’s eye to the face of the display shall be 20 in. (510 mm).

5. For control panels at which Operator is normally standing, displays and associated controls shall be located per Figure 9.4. Company’s Engineer shall approve control and display layouts—controls or displays requiring precise, frequent, or emergency use shall be located in a primary viewing area per Figure 9.3 and at a height of between 40 in. (1,015 mm) and 70 in. (1,780 mm) above the standing surface Figure 9.4.

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Figure 9.4 : Primary Visual Cone

6. Controls shall be positioned within the reach specified in Figure 9.4, close to and in clear relationship with the affected displays. Displays shall be arranged to be viewable from the normal working position.

7. Displays shall be perpendicular to Operator’s normal line of sight and clearly legible from expected viewing position (e.g., from the surveillance path or location of associated control) to reduce parallax error, and displays shall be located to avoid glare from nearby lights or sunlight.

8. For control panels at which Operator is normally seated, the control panels shall have the controls at least 26 in. (660 mm) above the floor and no more than 45 in. (1,145 mm) above the floor; however, 40 in. (1,015 mm) above the floor is the preferred maximum. For such seated control panels, the displays shall be at least 30 in. (760 mm) above the floor and no more than 60 in. (1,525 mm) above the floor; however, 48 in. (1,220 mm) above the floor is the preferred maximum. The instrument panels shall be approved by Company’s Engineer.

9. Light-Emitting Diode (LED) and Liquid Crystal Display (LCD) type displays shall be capable of being read in all possible illumination conditions without washout or loss of displayed information.

10. Equipment on console-type panels shall be arranged so that all instruments and switches are readable and operable by Operator in both the sitting and standing position. For console-type panels, the layout shall be approved by Company’s Engineer.

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Figure 9.5 : Position Displays and Controls

11. Annunciator pushbuttons shall be located together on the panel, within reach of Operator

and within readable distance of the respective annunciator window displays.

12. Doors on the back of the panel boards, doors on wall-mounted panels, or doors on equipment facing clearance aisles shall open without obstruction and shall give free access to the interior of the panels. Adequate access space for maintenance shall be provided. The minimum clearance acceptable is shown in Table 9.1.

Table 9.1 : Minimum Acceptable Clearance for Maintenance

WORKER POSITION

Standing

Stooping

Kneeling

Squatting

CLEARANCE DEPTH

28 in. (710 mm)

40 in. (1,020 mm)

48 in. (1220 mm)

36 in. (910 mm)

9.1.2 Safety Critical Controls and Displays

1. Switches on the front of the panel classified for emergency service shall be guarded to prevent accidental operation. Switches for regular process operation shall be a type not prone to accidental operation.

2. Safety-critical and high-accuracy controls and displays shall be placed within ±15 degrees of Operator’s central line of sight in horizontal and vertical directions. See Figure 9.3.

3. Safety-critical and emergency controls and displays shall be located separately from and be readily identifiable from those used normally for process control. They shall also be located within the “Safety Critical and Emergency Control” positioning for the control location for standing and sitting positions Figure 9.3, Figure 9.4 and Figure 9.5. These controls shall also be designed to be quickly activated.

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9.1.3 Spacing

1. Indoor controls shall be separated as indicated below, in order to avoid accidental

activation:

a. Pushbuttons, by 1 in. (25 mm)

b. Toggle switches, by 2 in. (50 mm)

c. Controls operated with the whole hand, by 5 in. (127 mm)

2. Adjacent keyboards on control consoles shall be spaced at least 30 in. (760 mm) apart,

center to center.

3. There shall be at least 54 in. (1,370 mm) clearance behind the chair to allow Operator

adequate access.

9.1.4 Sequence and Position

1. Progressions of quantitative display scales shall be in increments of 1, 2, 5, or multiples

thereof. Unusual progression systems, such as by 3, 8, etc., shall be avoided.

2. Multiple pointers and multiple scales shall be avoided on the same display.

3. A matrix of controls or displays should have an odd number of rows and columns. The

middle row or column improves spatial recognition of displayed devices.

4. Controls shall be arranged sequentially with respect to the intended order of operation. If three or more Operator actions must routinely be accomplished in the correct order to render a piece of equipment safe for manual intervention, then the control functions shall be combined in a single control with a label that describes the task (e.g., Maintenance Bypass). Boundary lines, coloring, or escutcheon plates shall be used to provide visual separation of groups. Adjacent displays with similar functions shall have the same layout of graduation marks and characters.

5. The position of discrete controls (e.g., pushbuttons, toggle switches, and rocker switches)

shall be easy to understand.

6. Mirror image control panels, controls, and displays shall not be used.

9.1.5 Display Convention

1. Gauge displays shall be black numerals and pointers on a white background.

2. All displays with similar functions shall have the same units of measure, layout of

graduation marks, and characters. Pointers shall not cover graduation marks.

3. All the numbers on displays shall increase in a clockwise, upward, or left-to-right direction.

9.1.6 Operability

1. Local controls and displays shall be selected and designed to facilitate manual operation and maintenance and shall be located with respect to each other using task analysis results.

2. Controls shall be selected considering the necessary functionality per Table 9.2 , the accuracy and speed of operation required, the force required to move them, and the available space, as indicated in Table 9.2 .

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Table 9.2 : Control Type Selection

CONSIDERATIONS

FUNCTIONALITY

LEVEL OF ACCURACY

ACTIVATION SPEED

ACTIVATION FORCE

AVAILABLE SPACE

REQUIRED CONTROL TYPE

Discrete with 2 Settings

High

Low

High

High

High

High

Small

Small

Large

Small

Toggle switch

Small

Pushbutton

Medium /Large

Rotary selector or lever

Discrete with 3 Settings

Discrete with 3 to 24 Settings

Continuous over a Small Range

Continuous over a Large Range

High

High

Small

Small

Toggle switch or thumbwheel

High

High

Low

High

High

High

Low

Low

Low

Low

Low

Low

High

High

High

High

High

Low

High

High

Low

Low

Low

High

Small

Small

Large

Small

Small

Large

Small

Large

Small

Small

Large

Large

Medium Rotary selector

Medium Rotary selector

Medium /Large

Lever

Small

Thumbwheel

Medium Rotary selector

Large

Handwheel

Small /Medium

Medium /Large

Small /Medium

Medium /Large

Slide switch

Lever

Knob

Crank

Large

Crank

Medium /Large

Foot pedal

1. Visual displays shall be selected considering the type of information that Operator needs to perform a task, as indicated in Table 9.3 . Unused displays shall be removed to avoid clutter and confusion.

2. Status indication minimum light size is 1/2 in. (13 mm), with luminance at least twice the

background luminance.

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Table 9.3 : Display Type Selection

INFORMATION NEEDED / TASK

EXAMPLES OF DATA

REQUIRED DISPLAY TYPE

COMMENTS

Quantitative Reading (an exact numerical value)

Production volume

Digital display

Qualitative Reading (approximate value, rate of change, or trend and magnitude of deviation from a desired value)

Temperature and pressure readings Process value changes during start-up Flow rates

Moving pointer Graph

Adjustment (setting an indicator to a desired value)

Status Indication (verification that a specific, discrete condition is or is not occurring)

Set point for instruments

Digital display Moving pointer

High pressure indicator

Status light Lighted message display

Fastest and most accurate to read. LCD more effective than LED in ambient light conditions.

Relative position is easy to notice, especially with zones marking acceptable operating ranges. Changes are easy to detect. Numbers shall increase in clockwise, upward, or left-to- right direction, and the scale shall be single and linear. Pointer shall not cover graduation marks. Color-coded zones help Operator make rapid qualitative readings.

Moving pointer has better stereotypes for control setting.

Fastest to comprehend. Can be alarmed at a flashing frequency of 2–3 Hz. Minimum light size is 1/2 in. (13 mm), with luminance at least twice the background luminance.

1. Permanent analog displays and gauges may be marked with color-coded zones to identify acceptable and unacceptable operating ranges and to ensure that monitoring and task execution is consistently and correctly performed. When color-coded zone markings are used, the zones shall be clear and understandable (e.g., red for danger, yellow for caution, green for acceptable). Gauges and displays shall additionally conform to Specification for field instruments.

2. Color coding as follows shall be used for operational controls:

a. Red for stop, failure, or malfunction

b. Yellow for caution

c. Green for acceptable or ready

d. White for standby or active

3. The movement of controls and the response of related displays shall be consistent and

predictable and shall conform to Operator expectations.

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4. All similar controls shall operate in a manner similar to one another.

5. Operation of controls shall be consistent with local and cultural expectations, to which people tend to revert under stress. Discrete controls shall have a positive indicator that the control has activated (e.g., indent, indication light, or large displacement of a switch). Controls installed outdoors shall be large enough to operate with gloved hands.

6. For safety-critical devices, and wherever possible for process control devices, Operator shall receive feedback that the final control element has responded to activation of the control device.

9.2 Minimum Requirements For Process Control Systems

9.2.1 Monitors

1. Design displays to be free of flicker when viewed from expected viewing distances and angles under normal control room lighting conditions. Include images at all brightness levels and large areas of color.

2. Ensure that the display image appears to be stable (i.e., free of “jitters”).

3. Select displays with a display luminance of at least 35 cd/m3. Preferred display luminance

is between 80 cd/m3 and 160 cd/m3.

4. Make controls for display contrast and color accessible to technicians but not to operators.

5. Ensure the displayed character height to width ratio is in the range of 1:1 to 5:3.

6. Ensure the displayed character stroke width to height ratio is in the range of 1:6 to 1:10.

9.2.2 Input/Pointing Devices

1. Provide the operator with a main input/pointing device and a back-up device (for example,

a tracker ball as the main input device backed up by a keyboard).

2. Make available to the operator dedicated function keys or display targets for frequent

operator inputs.

3. Locate frequently used input devices directly in front of the operator and within the primary

work zone.

4. Make, if possible, input devices such as keyboards height slope adjustable.

9.2.3 Printers

1. Choose printers that do not affect display content or updates.

2. Design printer systems that will not lose printed alarm information due to printer overload,

the paper supplies running out, or the printer being off-line.

3. Choose color printers for screen displays.

9.2.4 Dynamic Characteristics

1. Design the system to provide a clear indication to the operator when the keyboard is locked

out or the console otherwise disabled.

2. Design the system to provide a clear indication when updating of displayed information is

frozen or has failed.

3. Make multiple cursors distinct from each other.

9.2.5 System Security

1. Provide password and/or physical key lock protection for operator, supervisor, and

engineering access (optional for operators).

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2. Provide control or facilities to change display or input device characteristics to users with supervisor or engineering status. The access level (operator, supervisor, engineer) for functions such as control loop tuning, alarm suppression, lockout etc., shall be assignable by the systems engineer.

3. Provide date and time information to indicate the currency of time critical information.

4. Provide facilities to allow locking out system items that are undergoing maintenance and

show the locked out status on the display.

9.2.6 Data Integrity

1. Provide validation for all operator inputs to trap out-of-range requests.

2. Provide a clear indication to the operator when data is detected to be bad, lost, or

corrupted.

3. Do not allow a plant item to be controlled from more than one console at the same time.

4. Provide clear messages on system faults and indicate their consequences.

9.2.7 Information Presentation

1. Support the presentation of both overview and detailed information on plant status.

2. Select a system that will provide a means to build mimic display formats that incorporate

and give access to more detailed information when required.

3. Select a system that will provide a simple, standardized way to select and interact with displays not require the operator to learn any complex commands in order to use it.

4. Standardize the appearance and positioning of common features such as display titles,

menu bars, and operator input areas across all displays.

5. Provide the ability to provide eight different display colors (excluding flashing colors).

9.2.8 Alarm Presentation

1. Provide support for four priority levels for alarms. Allow a different presentation format (e.g., color, background, etc.) for every alarm level and give the systems engineering personnel control over this presentation format.

2. Provide the capability of suppressing or inhibiting intermittent, repeating alarms. Develop a list for the operator that indicates all suppressed / inhibited alarms and ensure that the data point on the display provides clear indication that the associated alarm is suppressed / inhibited.

3. Make possible to change the configuration of alarms for different operating states.

4. Enable the suppression of alarms that arise as a result of normal operations or following

a trip (e.g., low flow alarm when valve upstream is correctly closed).

5. Provide an audible alarm capability sounds a distinct alarm tone. Make the minimum required sound level (which is adjustable by engineering personnel) 10 dBA above ambient control room noise level.

6. Provide different and distinctive alarm sounds to differentiate between operating locations.

Design alarm sounds in the 500 Hz to 3000 Hz frequency range.

7. Provide alarm list display formats that enable alarms to be viewed by plant area, in order

of priority or in order of occurrence.

8. Make it possible to embed alarm information in mimic displays.

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9. Provide a means to directly access a display that shows the most recent, highest priority,

unacknowledged alarm.

10. Provide a simple means of directly accessing a suitable mimic display that provides details

of the earliest, highest priority alarm.

11. Do not allow an alarm to clear if the fault still exists.

12. Specify the use of colors that are significantly different from each other and use other

redundantly coding methods.

9.3 Visual Access For Visual Display Units

1. Proper functionality of Visual Display Units (VDUs) enables Operators to effectively monitor processes and manage abnormal situations. This Section provides basic requirements for designing VDUs. More specific guidance on meeting the criteria of this Section is provided in ASM Guidelines – Effective Console Operator HMI Design Practices [45].

2. Adequate visual access for shared displays shall be provided to each Operator sharing

the display.

3. Stacking of multiple VDUs shall be limited to two tiers, unless the third tier is a VDU that rarely changes, such as a display of a flare tip or unit historical data that is elevated and wall mounted.

4. VDUs within a control Operator’s work area, and preferably all VDUs within the control room, shall follow a common display convention (e.g., displaying the most recent alarm at the top of the screen).

5. Contrasting and consistent color code of the displayed item symbol and potentially the associated text as well shall be used to distinguish between and among equipment that is operating, is an idled spare, or is bypassed for maintenance.

6. Displays for separate groups of similar equipment, such as parallel compressor trains or coke drums, shall be clearly distinguished. For example, this may be done by prominently displaying large identifier letters (e.g., A and B) and/or by using a contrasting color in the screen background or a tag of contrasting color in the corner of the screen.

7. The type of display presentation and units displayed shall be consistent with the task that

Operator is expected to perform using the displayed information.

8. Figure 9.6 provides a selection of VDU types that are recommended for certain tasks.

9. Messages shall be brief and concise, using short, meaningful, and common words that

are presented in both upper and lower case lettering.

10. Numbers shall be horizontal (upright) and limited to the significant digits required for Operator to perform the task, with the leading character zero displayed before decimal values less than one. Units of measurement shall be indicated where appropriate. Digital numeric values shall not change faster than every 2 seconds. If it is important for Operators to be aware of the change, then trend analog displays shall be provided.

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Figure 9.6 : Examples of VDU Types Recommended for Specific Tasks

1. Symbols shall be consistent for all displays and shall match existing industry guidelines in BSI BS ISO 14617-6 [32] or ISA 5.5 [33] and the local site and cultural conventions. Each individual symbol shall represent only one object and be distinct from all other symbols.

2. Color shall not be used as the only means of identifying process components or conveying

important information.

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3. The meaning associated with each color shall be consistent within each display, shall be

distinct, and shall match Operator expectations.

4. No more than two levels of brightness coding shall be used. Brightness coding shall not

be used in conjunction with shape or size coding.

5. Display access structure shall be hierarchical, compatible with subdivisions of the unit or Operator activities, and grouped by function or location. The maximum number of hierarchical display pages on which process information is presented shall not exceed three.

6. A set of consistent overview displays applicable to each major mode of unit operation shall be designed and used to minimize the need to navigate between display pages. These overview displays shall provide Operator with necessary information for routine process monitoring, alarm status, and specific emergency response actions. Dedicated access keys for such display pages shall be provided.

7. Data input boxes shall be configured to reduce input errors, such as by using one of the

following examples:

a. Surround a plant item with a box.

b. Use a shaded background patch to indicate a selection area.

c. Change the cursor shape when it is over the selection area, and highlight the object

that has been selected for a subsequent input action.

8. For plant control functions, all inputs that change plant equipment status shall require all

of the following:

a. Explicit confirmation where the Operator confirms that status change.

b. Feedback that the input has been accepted or rejected, with a meaningful input

error message as appropriate.

c. Change of status on the display when the confirmatory signal is received from the

plant.

9. Visual access to wall-mounted displays and mimic boards shall be unimpeded. Critical displays in low light levels shall have character heights of 1.5 in. (38 mm) for every 15 ft (4.572 m) of viewing distance.

10. Video screens for flares and windsocks shall be easily viewed from all Operator workstations and located within the visual field as each Operator views the workstation monitor from a seated position.

9.3.1 Visual Display Units and Touchscreen Displays and Controls

1. At VDU control consoles, safety-critical and frequently used controls shall be within the primary reach envelope (defined as within reach while the elbow remains at the body side) of Operator seated in the upright work position, as shown in Figure 9.7. Other controls and communication equipment shall be within the secondary reach envelope of Operator in the forward leaning work position, as shown in Figure 9.8.

2. Whenever possible, touchscreen displays shall be positioned within the primary reach envelope and at an angle that minimizes glare and dust concerns. Pointing devices may be used with Company’s Engineer approval to reach touchscreens that are positioned outside of the primary reach envelope. See Figure 9.8 for recommended location of touchscreen VDUs if used.

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Figure 9.7 : Reach Envelope for Seated Operator

Figure 9.8 : Recommended Location of Touchscreen VDU

9.4 General Label Requirements For Displays And Controls

1. All display and control labels shall contain a functional descriptive phrase of the equipment on the top line of the label and a process tag number on the lower line. Terminology shall be consistent for the same controls used for different systems, and control position labels shall indicate the functional result of the control movement (e.g., ON, OFF, or BYPASS, increase or decrease).

2. Display label text shall be stated in terms of what is being measured and the units (e.g.,

voltage) instead of the display type (e.g., voltmeter).

3. Display and control labels shall be made of engraved plastic or vinyl or made of other

Company-approved environment-safe/resistant material.

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4. Labels shall be centered and placed above the controls and below the displays or, for displays, shall be an integral part of the display face; however, if small controls are mounted in a series one below another, then their individual labels shall be placed to the right. When a display is placed directly above its control, one label between them is sufficient and its units of measure shall appear on the face of the display, rather than on the label.

5. On control panels with many rows and/or columns of equally spaced controls and labels, labels shall be linked to the components they identify using tie lines or escutcheon plates (i.e., labels that enclose or surround the component). See Figure 9.9.

Figure 9.9 : Layout and Labelling of Controls and Displays on Control Panel

9.4.1 Specific Requirements for Fire and Gas Panels

1. Design fire / gas panels or VDU displays to rapidly and reliably identify the location and

spread of gas release or fire.

2. Indicate the location and activation of manual call points on fire and gas panels.

3. Group indicator lamps in a consistent layout and apply color-coding to ensure rapid and

reliable identification.

4. Identify alarm indications as they arise.

5. Arrange associated displays and controls so that they may be readily identified.

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6. Layout deluge or clean agent initiators to help guide the actions of the operator.

7. Clearly identify initiator controls (e.g., deluge and inert gas initiators) using human readable text labels. Use label text that is simple to understand, easy to read, and conforms to operator expectations.

8. Provide audible and visible alarms to identify power or communication failure.

9. Provide an integral lamp test facility to verify lamp integrity.

10. Provide a clear indication of where and how the fire and gas system has been overridden.

11. Provide a means to prevent inadvertent or unauthorized operation of fire and gas initiators.

9.4.2 Specific Requirements for ESD and Blowdown Panels

1. Display ESD alarms in such a way that the location and the source of initiation of the ESD,

or equipment affecting an ESD, may be readily identified.

2. Provide a single key press action to allow an operator to access alarm information on the

VDU process control system.

3. Locate a control for manual initiation of total plant ESD at the main control point, e.g., the

process control console.

4. Design a clear and simple relationship between the ESD and blowdown switches and the

equipment they control.

5. Identify and separate the controls for major plant areas and those for total plant ESD.

6. Design ESD controls to prevent accidental actuation.

7. Design displays relating to ESD / blowdown (e.g., panels or VDU displays) to permit the operator to quickly identify successful activation and to follow the progress of events.

8. Provide feedback information to confirm positively that the ESD / blowdown signal has

been sent and that ESD valves have closed and blowdown valves have opened.

9. Provide a direct correspondence between process control VDU mimics and the ESD /

blowdown panels.

10. Design audible and visible alarms to identify communications failure or malfunction in the

power supply.

11. Use audible and visible alarms to identify the failure of any single-channel, programmable

electronic system.

12. Provide an integral lamp test facility to verify lamp integrity.

13. Where arrangements are provided for overriding parts of the ESD system (e.g., during maintenance), provide a clear indication for parts of the system that have been overridden. Display this information at the main control point and local panels (e.g., wellhead panels).

14. Equip ESD systems with manual reset facilities.

15. Alert the operator at the main control point when an ESD is to be reset. Provide a system

for confirming or accepting resets.

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10

ISOLATION AND EMERGENCY SHUTDOWN DEVICES

This Section identifies the minimum requirements for integrating Human Factors principles into the selection of isolation devices, fire and gas panels, and ESD panels.

10.1 Abnormal Condition Detection And Local Initiation

1. Emergency alarm initiation points, call points, and ESD initiation points shall be installed

as specified in NFPA 72 [44]

2. A means to indicate the position or status of emergency controls shall be provided on or

near the controls.

3. Identification numbers and emergency contact numbers shall be clearly displayed. For items that are activated while standing, these shall be positioned 48 in. (1,220 mm) above the floor.

4. Where vocal communication is required, shielding and sound insulation shall be provided

where the noise from adjacent equipment exceeds 65 dBA.

5. ESD controls shall have some form of unique identification to clearly distinguish them from other controls (e.g., using labeling or color coding) and shall be adequately illuminated for poor visibility conditions. The function of an ESD button shall be made clear either by its location (e.g., next to a compressor) or by labeling, or both.

6. ESD controls shall be positioned between 40 in. and 55 in. (1,015 mm and 1,400 mm)

above floor level, as shown in Figure 9.4.

7. Emergency controls shall be capable of being activated quickly and easily, but shall be protected from inadvertent operation. The size of controls shall be appropriate for their expected mode of operation.

10.2 Abnormal Condition Detection At The Main Control Room

All controls and alarms shall meet the requirements listed in ASM Guidelines – Effective Console Operator HMI Design Practices [45].

10.3 Isolation Valves, Blinds, Switchgear And Other Devices

1. Devices for similar purposes shall have the same arrangement and appearance.

2. Visual indication shall be provided such that a visual inspection can determine that

isolation has been applied.

3. Visual indication of valve position shall be provided on drain line and vent line valves.

4. Ensure that Isolation devices designed for similar purposes have the same arrangement

and appearance.

5. Install permanent unique labels to clearly identify all isolation devices and to specify their

isolation function.

6. Design label information large enough to be accurately read from the expected working

distance.

7. Label valves/controls by item (i.e., by a human-readable description of its function) as well

as by the item’s tag number.

8. Provide lubrication points for valves and valve stems with an effective means for

lubrication

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9. Design the movement of isolation valves to be consistent, predictable, and compatible with operator expectations. The operating stereotype for valves is clockwise to close, counter- clockwise to increase flow, move left to right, front to back or upwards.

10. Provide adequate feedback to operators using isolation devices to indicate that the device

has been fully activated.

11. Provide a visual confirmation that isolation has been applied.

12. Provide a clear indication of open/close status on drain line/bleed off line valves.

13. Install physical interlocks, such as a captive key system, to control access to equipment

or ensure complete isolation prior to gaining access to hazardous areas.

14. Provide built-in isolation indicators or test systems to check the integrity of the isolation.

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