Human Factors in Plant Design

GP 17-05-01
Version 2
November 2002

Scope
1) [I] This Global Practice (GP) lists human factors requirements and considerations for the design and
installation of equipment in petroleum and chemical facilities. The objectives of these requirements
are to reduce risk of injury, specifically musculoskeletal disorders, and to minimize process upsets
caused by human error.
2) [I] The focus of this GP is the interaction of personnel with plant equipment in the following order:
a) Access for safe task performance
b) Controls and displays
c) Alarms
d) Signs, labels and color coding
e) Workplace environment
3) [I] An asterisk (*) indicates that additional information from the Owner’s Engineer, or approval by
the Owner’s Engineer is required.
GP 17-05-01 Human Factors in Plant Design November 2002

Table of Contents

Table of Figures.......................................................................................................................... 3

Table of Tables............................................................................................................................ 4

1. Required References ....................................................................................................... 5

1.1. ANSI–American National Standards Institute ..................................................... 5
1.2. ASSE–American Society of Safety Engineers.................................................... 5
1.3. ISA–The Instrumentation, Systems, and Automation Society.......................... 5
1.4. ISO–International Organization for Standardization.......................................... 5
2. Additional Requirements ................................................................................................ 5
2.1. Global Practices–ExxonMobil Engineering Practices........................................ 5
3. Definitions ........................................................................................................................... 9
3.1. Terms......................................................................................................................... 9
3.2. Acronyms ................................................................................................................10
4. Access for Safe Task Performance............................................................................10
4.1. Equipment Layout..................................................................................................10
4.2. Platforms, Stairs and Ladders .............................................................................11
4.3. Clearance................................................................................................................11
4.4. Access to Equipment ............................................................................................12
5. Controls and Displays ...................................................................................................13
5.1. Local Controls and Displays ................................................................................13
5.2. Local Control Panels and Control Consoles .....................................................17
5.3. Control Room Video Display Units .....................................................................19
5.4. Control Room Layout ............................................................................................21
6. Alarms ................................................................................................................................22

7. Signs, Labels and Color Coding .................................................................................22

8. Workplace Environment................................................................................................25

Record of Change....................................................................................................................26

Attachment: Purpose Codes Definitions ..........................................................................27

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Table of Figures
Figure 1: Location of Controls and Displays on Local Control Panels ....................14

Figure 2: Location of Controls and Video Display Units on Control Consoles .....18

Figure 3: Hazard Warning Signs.........................................................................................25

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Table of Tables
Table 1: Control Function Selection ..................................................................................15

Table 2: Display Function Selection ..................................................................................16

Table 3: Sign and Label Format (1) ......................................................................................23

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1. Required References
[I] This Section lists Practices and Standards that are generically referenced and assumed to be a part of
this document. Unless otherwise specified herein, use the latest edition.

1.1. ANSI–American National Standards Institute

ANSI Z35.1 (Withdrawn) Specifications for Accident Prevention Signs

1.2. ASSE–American Society of Safety Engineers

ASSE/SAFE A14.3 Safety Requirements for Fixed Ladders
ASSE/SAFE A1264.1 Safety Requirements for Workplace Floor and Wall Openings, Stairs, and
Railings Systems

1.3. ISA–The Instrumentation, Systems, and Automation Society

ISA 5.5 Graphic Symbols for Process Displays

1.4. ISO–International Organization for Standardization

ISO 3511-I Process Measurement Control Functions and Instrumentation - Symbolic
Representation - Part I: Basic Requirements First Edition

2. Additional Requirements
* [I] The following Practices shall be used with this Practice as specified by Purchaser.

2.1. Global Practices–ExxonMobil Engineering Practices

GP 01-01-01 Drawings, Diagrams, and Line Lists
GP 02-01-01 Plant Noise Design Criteria
GP 03-02-04 Pressure Relieving Systems
GP 03-02-07 Manual Sampling Systems
GP 03-03-02 Suction and Discharge Piping for Centrifugal Pumps
GP 03-03-03 Flushing and Drain Piping for Centrifugal and Rotary Gas Compressors
GP 03-03-05 Suction, Discharge, and Interstage Piping for Reciprocating Compressors
GP 03-03-07 Inlet and Exhaust Piping for Steam Turbines
GP 03-03-10 Strainers for Mechanical Equipment

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GP 03-04-01 Piping for Fired Equipment

GP 03-05-01 Fill and Discharge Lines, and Auxiliary Piping for Storage Tanks and
Vessels
GP 03-06-01 Piping for Instruments
GP 03-06-02 Piping at Control and Protective System Valve Stations
GP 03-06-03 Utility Connections to Piping and Equipment
GP 03-07-01 Piping Layout, Supports, and Flexibility
GP 03-12-01 Valve Selection
GP 03-16-01 Flanged Joints, Gaskets, and Bolting
GP 03-18-01 Piping Fabrication Shop or Field
GP 04-01-02 Structural Steel Design
GP 04-01-03 Design Loads for Structures
GP 04-02-01 Auxiliary Structures for Operation and Maintenance
GP 04-02-02 Pipe Supports
GP 04-03-01 Plant Buildings for Operation and Storage
GP 05-01-01 Pressure Vessels
GP 05-02-01 Internals for Towers, Drums, and Fixed Bed Reactors
GP 06-04-01 Air-Cooled Heat Exchangers
GP 07-01-01 Fired Heaters
GP 07-02-01 Industrial Boilers
GP 07-04-01 Burners for Fired Heaters
GP 07-08-01 Dampers and Guillotines for Fired Equipment
GP 07-10-01 Elevated Flare Tips
GP 08-01-01 Cooling Towers
GP 09-01-01 Spacing and Dikes for Storage Vessels and Tanks
GP 09-02-01 Additional Requirements for Pressure Storage Spheres
GP 09-06-01 Refrigerated Storage Tanks
GP 09-07-01 Accessories for Atmospheric Storage Tanks
GP 09-07-04 Internal Floating Roofs for Atmospheric Storage Tanks
GP 10-01-01 Centrifugal Pumps
GP 10-01-03 Shaft Sealing Systems for Centrifugal and Rotary Shaft Pumps
GP 10-02-02 Positive Displacement Pumps - Rotary
GP 10-03-01 Special Purpose Centrifugal Compressors

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GP 10-03-02 Packaged, Integrally Geared Centrifugal Air Compressors

GP 10-03-03 Rotary Screw Compressors
GP 10-03-04 Axial Compressors for Air Service
GP 10-04-01 Reciprocating Process Compressors
GP 10-07-02 Special Purpose Steam Turbines
GP 10-08-01 Combustion Gas Turbines
GP 10-09-01 Mechanical Agitators
GP 10-13-01 Special Purpose Centrifugal Fans
GP 10-13-02 General Purpose Centrifugal Fans
GP 10-14-01 Lube and Seal Oil Systems for Machinery
GP 14-01-01 External Insulation
GP 14-03-01 Fireproofing
GP 15-01-01 Instrumentation for Fired Heaters
GP 15-01-02 Instrumentation for Compressors and Drivers
GP 15-01-03 Instruments for Storage Tanks and Vessels
GP 15-02-01 Temperature Instruments
GP 15-03-01 Pressure Instruments
GP 15-04-01 Flow Instruments
GP 15-05-01 Level Instruments
GP 15-06-01 Electronic and Pneumatic Instruments
GP 15-06-03 Programmable Logic Controllers
GP 15-07-01 Electric Power Branch Circuit Design for Instrumentation
GP 15-07-02 Protective Systems
GP 15-07-03 Alarm Systems
GP 15-08-01 Process Stream Analyzers
GP 15-08-02 Sample Transport and Sample Conditioning Systems for Process Stream
Analyzers
GP 15-08-03 Combustible and Toxic Vapor Detection Systems
GP 15-09-01 Control Valves
GP 15-09-02 Electric Motor Operators for Valves
GP 15-10-01 Instrument Transmission Systems
GP 15-11-01 Instrument Control Panels
GP 15-12-01 Instrument Wire and Cable

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GP 16-02-01 Power System Design

GP 16-04-01 Grounding and Overvoltage Protection
GP 16-05-01 Lighting
GP 16-05-02 Security Lighting of Plants
GP 16-06-01 Substation Layout
GP 16-07-01 Motor Application
GP 16-08-01 Instrument and Essential Services Power Supplies
GP 16-09-01 Low Voltage AC Motors Up to 200 HP (150 kW)
GP 16-09-02 AC Motors: Medium Voltage and Low Voltage Over 200 HP (150 kW)
GP 16-09-03 Synchronous Generators
GP 16-10-01 Power Transformers
GP 16-12-01 Switchgear, Control Centers, and Bus Duct
GP 16-12-02 Secondary Selective Substations with Residual Voltage Based Automatic
Transfer
GP 16-14-01 Standard LV Variable Frequency Drives
GP 16-14-02 Engineered Variable Frequency Drive Systems
GP 17-01-01 Firefighting Equipment
GP 17-03-01 Emergency Shower and Eyewash Facilities
GP 19-01-01 Paint and Protective Coatings
GP 19-06-01 Facilities for Corrosion Monitoring in Process Equipment
GP 20-01-01 Inspection of Equipment and Materials
GP 20-01-03 Downstream Quality Programs

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3. Definitions
3.1. Terms
Term [I] Description
access An approach to equipment for reaching, inspecting or removing it,
characterized by sufficient space to allow unobstructed movement of the body
and by acceptable reach of personnel interacting with it.

accessible from grade Characterized by maximum horizontal reach of 20 in. (510 mm) or overhead
grip reach of 6 ft (1800 mm) when standing at grade level or on the top of
rolling stairs. Typically the maximum elevation of the stairs platform is
approximately 4 ft (1200 mm) so its railing can pass below pipes and
structures.
anthropometric data Data on human body sizes and dimensions to design or assess the appropriate
size of equipment for access and reach purposes.
clearance Space allowed for the passing of two parts, as it relates to headroom, knee
room, elbowroom, and access through passageways, around and between
equipment.
controls Devices an operator uses to change the status of equipment or process.
critical valve An emergency block valve (EBV).
displays Devices informing an operator about the status of equipment or process.
functional grouping A group or cluster of controls and displays that are all related to a particular
system.
glare Dazzling brightness within the field of vision that causes annoyance,
discomfort, or loss of visual performance and visibility.
horizontal reach The distance a specified group of people would be expected to reach,
measured from the shoulder to the fingertips with the arm extended out in a
horizontal plane.
input dialogue Means of interaction between an operator and the control system, such as
menus, direct interaction with graphics, typed commands, and selection of
function keys.
label A placard displaying several words and a code that is used to identify
equipment or components.
link analysis A technique to identify and optimize the links between system components in
terms of order, frequency and priority of use by the operator.
operational frequency The following terms used in GPs infer the indicated frequency of use:
for valves
a. Operating valve–at least four times a year.

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Term [I] Description

b. Frequently operated valve–more than twice a month.
operator interface The combination of display and controls devices that enable an operator to
communicate with the control system and to obtain information on the process
and equipment status.
population stereotype A convention adopted by a particular group of people (e.g., in the U.S., people
expect to switch up for on, in Europe people expect to switch up for off).
safety critical controls Devices that inform about abnormal conditions and which control variables
and displays requiring rapid change to avoid serious consequences such as loss of
containment, or injury.
sign A placard displaying text that is used to communicate instructions or
information.
symbol A graphic or icon that represents an action or object.
task analysis A systematic and structured break down of a task into its component steps for
the purpose of identifying potential hazards of the steps and respective risk-
reducing measures.
viewing distance Distance from the eye to the face of the display or other observed item.

3.2. Acronyms
Acronym [I] Description
DCS distributed control system
LCD liquid crystal diode
LED light emitting diode
SCBA self-contained breathing apparatus
VDU visual display unit

4. Access for Safe Task Performance

4.1. Equipment Layout

1) [O] 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. Mirror image layouts shall be
avoided and require approval from the Owner's Engineer.
Valve stations with similar purposes shall have similar arrangement and appearance.
2) [I] Layout of machinery and heat exchangers shall allow sufficient clearance and access to enable
removal with mobile hoisting equipment. Alternatively, fixed overhead lifting facilities shall be
provided as specified in GP 04-02-01.

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Additional requirements for lifting electric motors are specified in GP 16-09-01 and GP 16-09-02,
and for transformers in GP 16-10-01.
3) * [S] Location of SCBA and firefighting equipment specified in GP 17-01-01 shall be determined by
personnel usage of such equipment during emergency response (i.e., the emergency response task
analysis) and it shall be reviewed by the Owner's Engineer.

4.2. Platforms, Stairs and Ladders

1) * [I] Platforms shall be provided to the extent indicated in the GPs listed in Section 2.1 for the
equipment involved unless the equipment or facilities described are accessible from grade or from
other permanent platforms. Access to these platforms shall be by permanently installed stairs or
ladders unless otherwise specified.
Access to equipment from rolling stairs or mobile platforms shall be approved by the Owner's
Engineer.
2) [I] The arrangement of platforms, stairways and ladders, including access and exit locations, ladder
orientation, the type of safety swing gates, and the use of a rolling stair or platform in lieu of
permanent structures for access to equipment near grade, are specified in GP 04-02-01.
Stairs, not ladders, shall be provided where:
a) Personnel are required to carry large tools or pieces of equipment up or down the structure.
b) Equipment must be accessed or personnel evacuated during emergencies (e.g., battery limit
valves, manual sampling of dangerous materials).
c) Equipment is frequently accessed (at least once per shift on average).
Stairs and ladders to a platform shall not terminate in front of a manway.
3) [S] Indoor and outdoor stairs, ladders and platforms that could become slippery due to environmental
or production conditions shall be slip resistant.
4) [I] The required clear width and length of platforms for services typically experienced in process
facilities are listed in GP 04-02-01. Additional requirements for fired heaters are in GP 07-01-01, for
boilers in GP 07-02-01.
The elevation of a platform below the manhole centerline is specified in GP 04-02-01.
5) [O] The maximum horizontal reach from a platform or ladder shall not exceed 20 in. (510 mm). The
maximum overhead grip reach from grade or a platform shall not exceed 6 ft (1800 mm).
6) * [S] Access from a ladder onto the platform shall be through a self-closing safety gate defined in GP
04-02-01. Drop bars shall be approved by the Owner's Engineer.

4.3. Clearance
1) [I] The minimum vertical clearances between finished grade, paving or top of floor plate and the
bottom of piping, insulation or support beam (whichever controls) are listed in GP 03-07-01, GP 04-
02-01, and GP 04-02-02. Additional requirements for corrosion probe assemblies are in GP 19-06-
01, and for control valves, control valve actuators, and rodding out connections in GP 03-06-02.
The minimum vertical clearance under burners of fired heaters, measured to the lowest point of
overhead structural framing (including fireproofing), piping (including insulation), conduits, or
equivalent, shall be 6 ft 6 in. (1980 mm).
2) [I] Clearances at electrical equipment in indoor and outdoor substations, and in transformer yards are
listed in GP 16-06-01.

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3) [I] Personnel protection from hot surfaces is specified in GP 14-01-01. The minimum clearance
between the outside surface of any insulation system and adjacent equipment or structural members is
also specified in GP 14-01-01.

4.4. Access to Equipment

1) [I] Access to valves is specified in GP 03-07-01.
2) [I] Valve handwheels/handles shall be readily accessible and positioned to be within normal reach for
operation. Access shall be from permanent ladder, rolling stairs, platform, grade, or other means as
required for operations, maintenance, inspection and emission monitoring.
3) * [S] In order to avoid knuckle injuries, minimum clearance shall be 3 in. (80 mm) between adjacent
valve handwheels, equipment and structures; and 2 in. (50 mm) between the back of the handwheel
and insulation on the line. Additional clearance shall be provided for wrench-assisted operation of
valve handwheels and handles of ball-and-plug type valves. Use of valve wrenches shall be approved
by the Owner's Engineer.
Valve handles shall be oriented such that they do not turn to restrict the access or walk-through
pathway in front of the valve.
4) [S] Manual operation of valve handwheels, manual gear operators, levers, or chain operators shall not
require application of force exceeding 80 lb (38 kg). Operating valves that require a greater force to
turn, or that require more than 40 turns from open or close position, shall be motor-operated to reduce
the likelihood of musculoskeletal and repetitive motion injuries.
5) [O] Valves shall be selected and installed to ensure the consistent operating stereotype of increasing
flow when the actuator is turned counter-clockwise, moved from left to right, front to back or
upwards.
6) [I] Access to manual sampling facilities is specified in the following GPs:
a) Process streams in GP 03-02-07
b) Gas at compressors in GP 10-03-01
c) Flue gas at fired heaters in GP 15-01-01
7) [I] Access to field instruments is specified in GP 03-06-01, GP 15-01-03, GP 15-04-01, and to
instrument junction boxes in GP 15-10-01.
8) [I] Access to vents, drains, strainers, filters, and cleaning and flushing connections. Strainers, filters,
cleaning and flushing connections shall be accessible from grade or platform and with sufficient
clearance and lifting devices to facilitate: removal of strainer or filter media, use of rodding-out
devices, and connection of hoses for flushing.
Utility stations shall be located within a single hose length of the connections used in process
equipment and piping for cleaning and flushing. The hose length is specified in GP 03-07-01.
9) [I] Access to safety showers and eyewash stations is specified in GP 17-03-01.
10) [I] Access to fired heater components is specified in the following GPs:
a) Cabin, box and vertical cylindrical heaters, including observation doors, in GP 07-01-01.
b) Burners and pilots in GP 07-01-01 and GP 07-04-01.
c) Piping for burners and smothering steam in GP 03-04-01. The pilot gas valve and the igniter
switch shall be located to allow the operator lighting the pilot to see the pilot flame through an
observation port during the light-off procedure.

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11) [I] Access to boilers. Access beneath the boiler floor and requirements for observations doors are
specified in GP 07-02-01.
12) [I] Access to vessels. Manway requirements for vessel shells and skirts are specified in GP 05-01-01.
Access clearances and manway requirements through trays, grids and decks inside vessels are
specified in GP 05-02-01.
13) [I] Access to machinery for inspecting internal components is specified in GP 10-03-04, GP 10-13-01
and GP 10-13-02.
14) [I] Access to flare tips for servicing the pilot orifice is specified in GP 07-10-01.
15) [I] Access to cooling tower interior and exterior walls, air inlet louvers, drift eliminators, water
distribution systems and fans is specified in GP 08-01-01.
16) [I] Access to storage facilities is specified in the following GPs:
a) Spheres in GP 09-02-01.
b) Refrigerated storage tanks in GP 09-06-01.
c) Atmospheric storage tanks in GP 09-07-01.
d) External floating roofs in GP 09-07-01 and internal floating roofs in GP 09-07-04.
e) Diked enclosures of storage vessels and tanks in GP 09-01-01.
17) [I] Access to insulated equipment and piping components is specified in GP 14-01-01.
18) [I] Access to fireproofed instrument and electrical enclosures, and valve motor operators is specified
in GP 14-03-01.
19) [I] Access to electrical system components is specified in the following GPs:
a) Lighting fixtures in GP 16-05-01.
b) Indoor and outdoor substation equipment in GP 16-06-01.
c) Instrument and essential services power supply enclosures in GP 16-08-01.
Provisions shall be made for safe removal and replacement of batteries within enclosures.
Platforms shall be provided at exit doors to roll out the largest piece of equipment used in the
substation. The threshold design shall facilitate rolling the equipment to the platform.
20) [I] Blinds. Requirements for isolating equipment with blinds are specified in GP 03-07-01.
21) [O] Blinds heavier than 50 lb (25 kg) shall be equipped with a lifting handle. Blinds heavier than 100
lbs (50 kg) shall be oriented vertically and equipped for and accessible by a lifting device.

5. Controls and Displays

5.1. Local Controls and Displays
1) [O] Local controls and displays shall be selected and designed to facilitate manual operation and
maintenance, and located with respect to each other using task analysis results.
Controls shall be positioned within the reach specified in Figure 1, close to and in clear relationship
with the affected displays. Displays shall be arranged to be viewable from the normal working
position.

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Figure 1: Location of Controls and Displays on Local Control Panels

2030 80 STANDING CONTROL PANEL

Displays
1780 70

Controls Optimum
1525 60 48 to 64 in.
Optimum (1220 to
1270 40 to 55 in. 1625 mm)
50
(1050 to
1400 mm)
1015 40
Range Range
765 30 20 to 55 in. 20 to 64 in.
(510 to (510 to
1400 mm) 1625 mm)
510 20

255 10

0 0
mm Inches

Clearance
Minimum = 28 in. (710 mm)
Preferred = 35 in. (915 mm)

SIT DOWN CONTROL PANEL

Displays
1525 60
Range
30 to 60 in.
(750 to 1525 mm)
1270 50 Controls
Range 26 to 45 in. Optimum
1015 40 (650 to 1145 mm) 30 to 48 in.
Optimum (760 to
26 to 40 in. 1220 mm)
785 30 (660 to
1015 mm)

510 20

255 10

0 0
mm Inches

NOTES:
(1) Safety critical and high accuracy controls and displays, which require accurate and specific settings, shall be
located in the optimum range
(2) Gross controls and displays, which require low accuracy, can be located outside the optimum range.
(3) Dimensions in these charts are for the male Caucasian population. Dimensions for other populations are
available from EMBSI or EMRE

2) * [O] 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

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activated (i.e., indent, indication light, or large displacement of a switch). The controls installed
outdoors shall be large enough to operate with gloved hands.
In general, 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, the control functions shall be combined in a single control
that describes the task (e.g., maintenance bypass).
Controls shall be selected considering the accuracy and speed of operation, the force required to move
them, and the available space, as indicated in Table 1.

Table 1: Control Function Selection

Control
Accuracy Speed Force Space Recommended Control
Function

Discreet High High Small Small Toggle switch

(2 settings)
Low High Small Small Push button
High High Large Medium/Large Rotary selector, lever
Discreet High High Small Small Toggle switch, thumbwheel
(3 settings)
High High Small Medium Rotary selector
Discreet High High Small Medium Rotary selector
(3–24 settings)
Low High Large Medium/Large Lever
Continuous High High Small Small Thumbwheel
(small range)
High High Small Medium Rotary selector
High Low Large Large Handwheel
Low High Small Small/Medium Slide switch
Low High Large Medium/Large Lever
Continuous Low Low Small Small/Medium Knob
(large range)
Low Low Small Medium/Large Crank
Low Low Large Large Crank
Low High Large Medium/Large Foot pedal

3) * [O] Visual displays shall be selected considering the type of information that operator needs to
perform a task as indicated in Table 2. Unused displays shall be removed to avoid clutter and
confusion.
Displays shall be perpendicular to the operator's normal line of sight (e.g., from the surveillance path)
to reduce parallax error, and mounted to avoid glare from nearby lights or sunlight.
Displays shall be placed above their associated controls, and if this is not possible, then to the left of
the controls. Display that is not adjacent to the control shall be visible from the control.
Permanent displays shall 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. This will result in safer and more reliable equipment operation. For example, transparent
color decals may be used on gauge dials, and non-glass components of level gauge columns may be
painted.

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Table 2: Display Function Selection

Information Recommen
Examples of Data Comments
Needed/Task ded Display

Quantitative reading Production volume Digital Fastest and most accurate to read
(an exact numerical value) display
LCD more effective than LED in ambient
light conditions
Qualitative reading Temperature and Moving Relative position is easy to notice, especially
(approximate value, rate of pressure readings, pointer with zones marking acceptable operating
change, or trend and process value ranges
magnitude of deviation changes during
Changes are easy to detect
from a desired value) startup, flow rates Graph
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 make rapid qualitative
readings
Adjustment Set point for Digital Moving pointer has better stereotypes for
(setting an indicator to a instruments display control setting
desired value)
Moving
pointer
Status indication High pressure Status light Fastest to comprehend
(verification that a specific, indicator
Lighted Can be alarmed at a flashing rate of 2–3 Hz
discrete condition is or is
message
not occurring) Min. light size 1 /2 in. (13 mm), luminance at
display
least twice the background luminance

4) [O] Displays shall be located such that they are visually accessible from normal work positions,
without resorting to use of ladders, or 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
no less than 20 in. (510 mm) and the maximum viewing distance, defined by legibility limitations,
shall not exceed the font size multiplied by 200 (in the same units of measurement).
The character size on a display shall be at least 1 /8 in. (3.5 mm) for a viewing distance that is less than
28 in. (700 mm). Black numerals and pointers on a white background are preferred.
Progressions of quantitative display scales shall be by 1's, 2's, or 5's or multiples thereof. Unusual
progression systems such as by 3's, 8's, etc. shall be avoided.

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5.2. Local Control Panels and Control Consoles

1) [O] Local equipment control panels shall be located for visual access from the expected location of
the operator to the necessary information on the panel. Adequate lighting, glare avoidance and
maintenance access shall be considered.
2) * [S] Ergonomic design of control consoles will help reduce the likelihood of musculoskeletal
disorders. The work surface height and the clearance under the work surface of a console shall be
determined from anthropometric data charts developed for local populations.
There shall be at least 54 in. (1370 mm) clearance behind the chair to allow operator adequate access.
3) * [O] Controls and associated displays necessary to support an operator activity or sequence of
activities shall be grouped together. Boundary lines and coloring may be used to provide visual
separation of groups. Adjacent displays with similar functions shall have the same layout of
graduation marks and characters.
A matrix of controls or displays shall have an odd number of rows and columns. The middle row or
column improves spatial recognition of displayed devices.
4) * [S] Controls and displays on local equipment control panels and auxiliary panels in control rooms
shall be located as per Figure 1. The breadth of the control panel shall consider access to all controls
from the operator's normal work position. Mirror image control panels shall be avoided and require
approval of the Owner's Engineer.
Safety critical and high accuracy controls and displays shall be placed in the indicated optimum
ranges, which are within ±15 degrees of the operator's central line of sight in horizontal and vertical
directions.
Safety critical controls and displays shall be located separately from those used normally for process
control.
5) [O] As a minimum, controls shall be separated as indicated below in order to avoid accidental
activation:
a) Push buttons by 1 in. (25 mm)
b) Toggle switches by 2 in. (50 mm)
c) Controls operated with the whole hand by 5 in. (125 mm).
6) * [S] At VDU control consoles, safety critical and frequently used controls shall be in the primary
reach envelope of the operator seated in the upright work position, which is defined as within reach
while the elbow remains at the body side. Other controls and communication equipment shall be
within the secondary reach envelope of the operator in the forward leaning work position, as per
Figure 2.

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Figure 2: Location of Controls and Video Display Units on Control Consoles

Secondary
Reach
Envelope

Primary
Reach
Envelope

Forward Reach
_ 21 in.
<
(530mm)

Touch screen displays shall be positioned within the primary reach envelope and at an angle that
minimizes glare and dust concerns. The Owner's Engineer shall approve the use of pointing devices
to reach touch screens positioned too far away.
7) [O] Adjacent keyboards on control consoles shall be spaced at least 30 in. (760 mm) center-to-center.
8) [O] Displays shall be placed above their associated controls. If this is not possible, they shall be
placed to the left of their controls. Any display that is not adjacent to the control shall be visible from
the control.
The movement of controls and the response of related displays shall be consistent, predictable, and
shall conform to operator expectations. (For example, if the handwheel, lever or switch is turned to
the right or clockwise, the pointer on a circular scale shall move to the right or clockwise and on a
vertical scale upwards).
9) [S] For safety critical devices, and wherever possible for process control devices, operator shall
receive feedback that the final control element responded to activating the control device.
10) [O] All controls and displays shall have individual labels that consist of a functional description of the
control or display and the tag number. Terminology shall be consistent between same controls used
for different systems and control position labels shall indicate the functional result of the control
movement (e.g., ON, OFF, BYPASS).
11) [O] Labels shall be centered and placed above the controls and below the displays, or be an integral
part of the display face. When a display is placed directly above its control, one label between them
is sufficient. Units of measure shall appear on the face of the display, rather than on the label. If

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small controls are mounted in a series one below another, their individual labels shall be placed to the
right.
On control panels with many rows and/or columns of equally spaced components and labels, labels
shall be connected to the components they identify using tie lines or escutcheon plates (i.e., labels that
enclose or surround the component).
12) [I] Illumination and glare avoidance requirements for control panels and consoles are listed in GP 16-
05-01.
13) [M] Component access. Items that are frequently pulled out of their installed positions for inspection
and/or testing shall be mounted on rollout racks, slides, or hinges. These shall be free to open or
rotate the full distance, and remain held in the open position without an additional support (e.g., with
hand).
14) [M] Components located in a cabinet higher than 48 in. from the floor shall be installed in vertically
mounted drawers to facilitate access and reduce potential for error. At lower heights, modules in
cabinets shall be horizontally mounted in slide-out drawers or chassis.

5.3. Control Room Video Display Units

1) * [I] Functionality of VDUs enables operators to effectively monitor the process and manage
abnormal situations. This Section provides basic requirements for designing VDUs. More specific
criteria for assessing whether operating displays provide appropriate and sufficient functionality, and
specific guidance on meeting the criteria is provided in the ASM Consortium "Guidelines for
Effective Operator Display Design."
2) [O] Stacking of multiple VDUs shall be limited to two tiers, unless the third tier is a VDU that rarely
changes, like a display of a flare tip, as illustrated in Figure 2. The picture shall be stable since, when
viewed in peripheral vision, auto cycling pictures are a source of distraction.
3) [O] VDUs within the control post, and preferably within the control room, shall follow a common
display convention. For example, displaying the most recent alarm at the top of the screen.
4) [S] Contrasting and consistent color code of the displayed item symbol, and/or a text label, shall be
used to distinguish between an equipment that is operating, idled spare, or bypassed for maintenance.
Priority 1 and lower alarms shall not be used for such purposes, as such a practice increases the
number of active alarms.
Similar convention shall be used to distinguish between control loops in automatic, manual, or
bypassed modes.
5) [O] Displays for separate groups of similar equipment, such as parallel compressor trains or coke
drums, shall be clearly distinguished, for example by prominently displaying a large identifier letter
(e.g., A and B) or tag of contrasting color in the corner of the screen.
6) [O] The type of display presentation shall be consistent with the task the operator is expected to
perform using the displayed information.
7) * [O] Displayed values shall be consistent with the values documented in relevant operating manuals.
Such values shall be approved by the Owner's Engineer.
8) [O] Displayed characters shall be clearly legible from all expected viewing positions. Typically for
consoles, minimum acceptable character height is 1 /8 in. (3.5 mm) based on maximum viewing
distance of 28 in. (700 mm) and 3 /16 in. (5 mm) for items that are scanned from a distance (e.g.,
symbols).

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a) Label shall be presented horizontally with text in capital letters.

b) Italic, bold and underline font shall not be used.
c) Labels shall use the fewest characters, common abbreviations with no periods, and words
meaningful to operators and consistent with the operating procedures.
d) Tags longer than four characters shall be split into blocks of two to four characters separated by a
blank space. Parts of the tag common to the entire process unit shall not be displayed.
9) [O] Messages shall be brief and concise, use short, meaningful and common words, and be presented
in both upper and lower case text.
10) * [O] Numbers shall be upright, limited to the significant digits required for the operator to perform
the task, with the leading zero displayed in decimals. Units of measurement shall be indicated where
appropriate. Digital numeric values shall not change faster than every two seconds; if it is important
for operators to be aware of the change, trend analog displays shall be provided.
11) [O] Symbols shall be consistent for all displays, and match existing industry guidelines in ISO 3511-I
or ISA 5.5 and the local site and cultural stereotypes. Each individual symbol shall represent only
one object and be distinct from all other symbols.
12) [O] Main flow lines shall be distinguished from lines for secondary flows and utilities; all flow path
lines shall have arrowheads indicating the flow direction and be labeled at the entry and exit of the
display or the start/end at labeled components. Process lines should not cross, and where a crossover
is inevitable, it shall be clearly distinguished from connections at the maximum expected viewing
distance.
A maximum of three displayed line types (e.g., solid, dashed) and three line widths shall be used to
distinguish between different flow lines.
13) [O] Color shall not be used as the only means of identifying process components or of conveying
important information. Redundant use of color accommodates color vision deficiencies among
operators, partial display failures, or color shifts caused by display aging.
Color may be used redundantly to improve the clarity of displayed information:
a) As an identification code for distinguishing between categories of items (e.g., bright color to
indicate running or open, dull color or empty symbol to indicate stopped or closed; bright color
and text label to indicate the contents of flow lines, dull color for utility lines).
Bright colors at the red end of the spectrum tend to stand out from duller colors at the blue end of
the spectrum.
b) By highlighting key items of information on a display (e.g., alarm indications).
c) By reducing the perceived clutter from background graphics and information of secondary
importance (e.g., vessel symbols and tags).
14) [O] Meaning associated with color shall be consistent within each display, shall be distinct, and shall
match operator expectations (e.g., standing red alarm symbols can be obscured in a display, which
also uses red for indicating a valve status). No more than seven colors shall be used for identification
coding purposes. Compatible background and foreground color combinations are as follows:

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Foreground Color Recommended Background Colors

White Blue, Green
Blue White, Yellow, Cyan
Orange Black
Yellow Black
Cyan Black

15) [O] No more than two levels of brightness coding shall be used. Brightness coding shall not be used
in conjunction with shape or size coding.
16) [O] Display access structure shall be hierarchical, compatible with subdivisions of the unit or operator
activities, and grouped by function or location. The maximum level of pages on which process
information is presented shall not exceed three.
A set of consistent overview displays applicable to each major mode of unit operation shall be
designed to minimize the need to navigate between display pages. Such displays shall provide
operator with necessary information for routine process monitoring, alarm status, and specific
emergency response actions. Dedicated page access keys for such displays shall be provided.
17) [O] Input dialogues shall be configured to reduce input errors. For example, surround plant item by a
box, or use a shaded background patch to indicate a selection area, or change the cursor shape when it
is over the selection area, and highlight the object that has been selected for a subsequent input action.
For plant control functions all inputs that change plant equipment status shall require all of the
following:
a) Explicit confirmation
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

5.4. Control Room Layout

1) * [O] Process control work area arrangement. Equipment in the control room shall be grouped
considering operator functions. Link analysis shall be used during the control room layout design to
determine anticipated interactions between operators and between operators and equipment. All
visual and auditory activities shall be included. Crossovers, unnecessary steps and repetitious
pathways shall be minimized.
Space shall be provided at the consoles for placing emergency response and frequently used operating
procedures.
2) [O] Displays with information necessary to perform control functions, but that are located outside the
control console, shall be within the operator's functional visual field (within ±30 degrees of the
central line-of-sight from the normal/seated work position). To be legible, the minimum height of
characters on such displays shall equal the viewing distance divided by 200.
3) [O] Permitting work area. A permitting work area in the control room shall have adequate
workspace, a board to display permits, and space for any drawings and forms that operators may need
to access.

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6. Alarms
1) [S] Alarms shall be located so they are audible and visible.
2) [S] Alarms shall be prioritized considering the consequences of the event and the required urgency of
operator response. To reduce the number of nuisance alarms during process upsets the normal
distribution of alarms among priority levels shall be as follows:

Alarm Priority Distribution

Priority 'E' Emergency or Priority 1 10–15%
Priority 'H' High or Priority 2 35–40%
Priority 'L' Alerts/Notifications or Priority 3 50–55%
Alarms and Alerts for Single Control Loop 2–4

3) [S] On the control console at least one VDU shall be dedicated to displaying alarm summary
information. That VDU as well as any dedicated alarm on the console shall be located within ±15
degrees of the operator's central line of sight in horizontal and vertical directions at the normal work
position.
Operator shall be able to acknowledge an alarm only from a display that provides details of the alarm.
4) * [S] The sound level of audible alarms shall be set around 10 dB(A) above the ambient background
noise level at all locations within the operators' expected working area. The maximum alarm volume
shall not exceed 80 dB(A) within the control room.
The total number of distinct alarm tones at the same location, used to differentiate between alarm
source and priority, shall not exceed four.

7. Signs, Labels and Color Coding

1) [O] All equipment used during operations or maintenance shall be labeled.
2) [O] To enable plant personnel to correctly and consistently understand the intended message of a sign
or label, components of each sign or label (e.g., text, symbols, and color) shall be presented in a
consistent and appropriate style and arranged in a consistent format.
Tags on equipment, drawings, controls and displays, and in operating manuals, as well as
corresponding symbols, shall be consistent with GP 01-01-01 and local visual monitoring standards.
Tags shall be presented in the upper case letters.
3) [O] Text. Short, positive phrases or sentences shall be used with abbreviations and acronyms that are
standardized, consistent and commonly familiar at the location.
All text shall be written in a bold, Sans Serif font (e.g., Helvetica, Arial). Italics and underlining shall
be avoided.
Text character height is related to the viewing distance and shall be at least the viewing distance
divided by 200 (in the same units of measure). The character width shall not be less than 70 percent
of the character height and the character stroke width less than 1 /8 of the character height.

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Text shall be oriented horizontally. Mixed case letters (i.e., both upper and lower) are preferred for
sentences or phrases of more than two words. All upper case letters are acceptable for one to two
words only. Long procedural instructions shall be left justified and numbered. Short sentences or
phrases shall be centered. Breaking a line and starting a new line of text where the meaning may be
obscured or misinterpreted shall be avoided.
Information on the sign or label shall be arranged consistently. The recommended format is shown in
Table 3.

Table 3: Sign and Label Format (1)

Sign or Label
Format Example
Type
Piping Label First line: Piping contents (text required, color code PS-7 Feed
optional)
Second line: From/To (if deemed of value) From TK-301 To V-101
Equipment First line: Functional description FG Scrubber
Label
Second line: Tag number V-401
Control Panel First line: Equipment or process description Feed to F-101, Pass 4
Label
Second line: Functional description Low Flow
Third line: Tag number FLA-314

Warning Sign First line: "Signal word" rating the hazard (DANGER, DANGER
CAUTION)
Second line: Hazard description/consequence High Voltage
Third and subsequent lines: Means/ways to avoid the Authorized Personnel
hazard Only
Note (1): Labels for electrical cabinets, panels, and equipment shall indicate the maximum
voltage present.

4) [O] Symbols. Symbols, in addition to text on signs or labels help personnel, who have difficulty
understanding text, particularly where more than one language is commonly used. Preferably,
symbols shall supplement the text of a sign or label.
5) [S] Color. Labels and signs shall have black text on white background. A black border added to the
white background may be used to enhance the contrast between the sign or label and the background
surface. Colored text shall only be used for hazard warning signs, and shall be consistent with the
plant and cultural stereotypes. Black text shall be used on yellow background, and white text on red,
blue and green backgrounds. Other color combinations shall be approved by the Owner's Engineer.
6) [O] Location. A sign or label shall be placed within the expected line of sight of all potential users. It
shall be mounted on, at, or adjacent to the equipment or process to which it relates, facing the
viewer's expected approach direction. Maintenance activities shall be considered in locating labels
and signs to protect them from being removed and/or damaged.
Duplicate internal signs shall be provided where external signs are attached to removable panels.
Signs shall not be placed where an opened door can cover them.

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7) [O] For piping systems, labels shall be placed at inlets and outlets to equipment, at valves, on both
sides of a penetration, at branch connections, and about every 50 ft (15 m) on straight runs. On
vertical lines, labels may be rotated clockwise 90 degrees to make the text readable from the expected
viewing position. Arrows indicating the flow direction shall point away from the text and have solid
(filled) shapes.
8) [O] Text of labels for cables and wires shall be a single line in upper case letters with the minimum
character size 6 to 8 point, preferably in Helvetica font. For vertical cables and wires, the label shall
be rotated clockwise 90 degrees.
9) [O] Material. Materials used for signs and labels shall be resistant to the environment where they are
mounted. All outdoor signs and labels shall be resistant to UV exposure. Engraved lettering shall not
be used in environments containing dust and debris.
10) [O] Equipment signs may provide supplementary information relating to performance or equipment
use (for example, task instructions). In such signs, short, simple, positive sentences shall be presented
in mixed case letters. The signs shall be mounted at the position from which the person will control
the equipment.
Step-by-step procedures shall be numbered and left justified.
For non-procedural information line spacing or indentation can be used to separate the information.
11) [S] Hazard warning signs. Hazard warning signs, illustrated in Figure 3, shall alert the viewer and
describe the hazardous conditions. Some signs may also convey the measures or evasive actions to
prevent the hazard from occurring, and/or explain consequences of the hazard. The signs shall be
mounted at, on, or adjacent to the source of hazard, at a distance adequate to alert the viewer in
sufficient time to take evasive action, and approximately 60 in. (1520 mm) above the work or
approach surface.
All text shall be in bold, Sans Serif font with the signal word in capital letters and the rest of the text
in mixed case letters. The character size for the signal word shall equal the safe viewing distance
divided by 150, and for other text the distance divided by 300. The text message shall be concise
with active and affirmative words.
Danger related signs shall use recognizable symbols in addition to the text to clarify the meaning of
the sign. The preferred color combination is the signal word DANGER in white letters on red oval or
rectangular background and the other text in black or red letters on white background.
On caution signs, the signal word CAUTION shall be in yellow letters within a black rectangular
background and the other text in black letters on yellow background.

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Figure 3: Hazard Warning Signs

white red yellow

black black
DANGER CAUTION
Process Streams May Hearing Protection
Contain Hydrogen Sulfide Required

SIGNAL WORD
(2 line space)
Hazard Description
(1 line space)
Consequences and Prevention Measures

12) [O] Information signs. Signal words ATTENTION, or NOTICE may be used on non-hazard
information signs. Longer instructions shall be broken into steps and left justified. Commonly
recognizable symbols may be used in such signs and they shall always be accompanied by text.

8. Workplace Environment
1) [I] Lighting requirements are specified in GP 16-05-01, emergency lighting in GP 16-05-01, and
security lighting in GP 16-05-02. Additional requirements for lighting at emergency shower and
eyewash facilities are listed in GP 17-03-01 and at manual sampling facilities in GP 03-02-07.
2) [I] Requirements for locating indoor and outdoor convenience electrical outlets to serve portable
lights and tools are specified in GP 16-02-01 and GP 16-06-01.
3) [S] Temperature, ventilation and air flow. In occupied buildings humidity shall be maintained
between 20–60 percent with the preferred range of 40–45 percent to help prevent irritation and drying
of body tissues, eyes, skin and respiratory tract. The combination of moderate cold and high humidity
is experienced as unpleasant, and hence, acts as a stressor that could contribute to erroneous
performance.
Air in the control room shall be replaced at a rate of 15 ft3 /min (0.43 m3 /min) per person with
approximately two-thirds consisting of the makeup fresh air. The flow velocity of air shall not exceed
45 ft/min (0.2 m/s).
4) [I] Noise levels shall be controlled to ensure that voice communication is unhindered, auditory alarms
are noticeable, background noise levels are not irritating or tiring, and that potential for hearing
damage is reduced.

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Record of Change

Common
Version 2 Date: 11/02
Location Action Description

Figure 1 Modification Added scale to left, and minimum and preferred clearances below the
standing control figure
Figure R2 Modification Added the following note below figure, "Note: Heights measured to
handwheel centerline. Heights are to the maximum extension of valve
stem for rising stem valves."

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Attachment: Purpose Codes Definitions

Code Definition
C Assigned to paragraphs containing specifications whose primary purpose is reduced costs.
Reduced cost in this context refers to initial investment cost, and does not include Life Cycle cost
considerations. Life Cycle considerations are captured under reliability, maintainability or
operability purpose codes.
E Assigned to paragraphs containing specifications whose primary purpose is driven by
environmental considerations. Environmental considerations typically include specifications
intended to protect against emissions/leakage to the air, water and/or soil. Deviations from the
specifications contained in such paragraphs require formal review and approval according to
local environmental policy.
I Assigned to paragraphs that provide only clarifying information such as Scope statements,
definitions of terms, etc.
M Assigned to paragraphs containing specifications whose primary purpose is to provide for
maintainability of equipment or systems. Maintainability provisions are those that facilitate the
performance of maintenance on equipment/systems either during downtimes or during on-stream
operations.
O Assigned to paragraphs containing specifications whose primary purpose is to assure operability
of equipment or systems. Operability is the ability of the equipment/system to perform
satisfactorily even though conditions are off-design, such as during start-ups, process swings,
subcomponent malfunction, etc.
R Assigned to paragraphs containing specifications whose primary purpose is to improve or assure
the reliability of equipment or systems. Reliability is a measure of the ability of
equipment/systems to operate without malfunction or failure between planned maintenance
interventions.
S Assigned to paragraphs containing specifications whose primary purpose is avoidance of
personnel or operational safety incidents. Any deviation from the specifications contained in
such designated paragraphs requires formal review and approval according to local safety policy.
Personnel Safety: Refers to the avoidance of recordable personnel injuries, i.e. burns, cuts,
abrasions, inhalation or exposure to dangerous substances, etc., that could
result in medical treatment, restricted work, lost-time incidents or fatalities.

Operational Safety: Refers to the prevention and control of process releases, fires, explosions,
etc.

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