By Craig Resnick, ARC Advisory Group
ABB recently briefed ARC regarding their System 800xA, with a special focus on collaboration tools between the System 800xA and those responsible for operation of the system. ABB is putting the operator in focus and creating new ergonomic standards for control rooms that utilize their System 800xA. This is part of a trend that ARC refers to as “Ergonometrics”, where increased ergonomics leads to increases in KPIs and metric results. ABB’s objective is to offer the operator an attractive working environment with extended functionality, which better enables functional consolidation and increases collaboration. The key component of this offering is the Extended Operator Workplace, which provides detailed overview images of the entire process with high definition graphics. This solution creates an optimized working environment for the operators and meets high ergonomical standards, making it more possible for the operators to act fast in critical situations and avoid expensive shutdowns.
System 800xA is a key component of ABB’s Industrial IT. The goal of Industrial IT is to expand the role of industrial automation beyond that of a traditional DCS system by integrating the domain of traditional process control with the domain of IT technologies and applications. Industrial IT solutions deliver measurable increases in productivity that include and extend beyond plant automation. Industrial IT is ABB’s solution for collaborative process automation. Within this context, Industrial IT integrates System 800xA with other ABB and 3rd party products to support the complete operational and lifecycle needs of the customers’ manufacturing processes.
The System 800xA Extended Operator Workplace is designed to provide extended graphics in a personalized HMI design environment, with extensive view handling and navigation features as well as support for multiple monitors and large screens. The workplace is incorporated into an integrated control room layout and ergonomic design, which consists of fully adjustable furniture with selectable materials and colors, optimized lighting and noise conditions, customized visualization solutions for different requirements, personalized close large overview displays for interactive work, and large background displays for static information in either front or back projection with different types of flat monitors for individual needs. Data and system integration consists of live video aspects on process objects, video group displays, embedded video in process displays, video history with recording to hard disk, snapshot of images, and camera faceplate with control of camera directly from the operator screen. Additional integrated functionality includes telecommunication applications such as voice communication and integrated public address systems with context sensitive access, critical alarms that are automatically generated for the operator with a selection of alternative message and languages, access to general messages from a list and open entry of new messages, and on-line documentation, maintenance data, and business systems. More information on The System 800xA Extended Operator Workplace can be found at 800xA Extended Operator Workplace on abb.com and http://www.cgm.se/ .
Success stories with ABB System 800xA Extended Operator Workplace include an iron mine modernization project, with a goal to increase the safety and operational efficiency of the plant, along with improved ergonomic and comfort conditions for the operators. Results included improved productivity of the operators who work in the control room, extended internal processes, better flow of information between different job teams, such as the maintenance and instrumentation groups, and substantial improvement in operator morale and job enthusiasm.
Another case is a methanol plant upgrade project that resulted in integrated live video capabilities including IR cameras for temperature supervision, extended presentation of KPIs, and new simulators for operator training along with substantially improved ergonomics.
A major project under study involves a gas receiving terminal with a focus on improved operator effectiveness and integrated telecommunication applications, voice communication, and public address broadcasting of messages. The customers feel that increased operator effectiveness is a true differentiator, as is the integration platform for data as well as a large screen solution with the operator as the focus.
In summary, ARC feels that increased “Ergonometrics” is a direct result of increased operator workplace ergonomics and design, and does have a positive impact on operational performance. Well designed HMI screens and console furnishings do enable operators to be more effective. Benefits to system operators go beyond operations and also include personnel benefits. Design and implementation of control rooms and HMIs should include ergonomics as a key factor. ABB should aggressively promote these practices, collaborate with their manufacturer and processor customers, and propose solutions and implementation approaches that include System 800xA solutions with an ergonomically inspired Extended Operator Workplace and furnishings.