Coastal Refinery Control Room Upgrade
One operator, one view, plant still running
After a restructuring cut console operators by almost half, we redesigned a Western Cape refinery’s central control room so each operator sees all their units from one position. The room stayed live throughout.
We carried the work from concept design to fit-out between 2023 and 2024.
Three layouts, one choice
We developed three layout options, then a final layout with 3D views.
Six operator groups
We regrouped the plant so each operator sees their units and critical alarms from one position.
Console design and supply
Six height-adjustable consoles in two pods of three, carrying 21 stations and 48 monitors.
Video wall and distribution
We designed and supplied the video wall and the video distribution behind it.
Ceiling, lighting and power
Concept design covered ceiling, lighting and power, followed by the interior fit-out on site.
How It Was Delivered
One group at a time
We installed one operator group at a time. Operators moved to a temporary position while their console was replaced.
Phased live changeover
Train before the switch
The last console was pre-installed in the equipment room. Operators trained on it before it went into service.
Operator training first
Nights and weekends
Night shifts and weekend work kept the plant controlled during each changeover. We supplied site supervision and quality control throughout.
Supervision and quality control
At a Glance
6
height-adjustable consoles in two pods of three
21
operator and alarm stations
48
monitors across the six consoles
5 weeks
site fit-out, with the control room live
Client and site names are not published. See all projects.
The challenge
After a restructuring, the refinery cut its console operators by almost half. The plant did not shrink with the team. Each operator now had to watch 8 to 10 screens. To see their units, they switched between displays or walked around the room.
The client’s own requirement said this was “not conducive to a safe and high performing control room”.
The answer had to be built inside a working control room. The refinery could not stop for a rebuild. Every change had to be planned around live operation, one area at a time.
The result
Each operator now works from one position. DCS operator and alarm stations, tank gauging, fire and gas, radio, telephony and emergency stops are all within reach. The video wall is in view from each position.
Operators no longer walk the room to see their units. The plant is split into 6 operator groups that match the smaller team.
The refinery kept running through the whole upgrade. Site fit-out took about 5 weeks. One firm carried the work from the first layout option to supply, fit-out and supervision.
Frequently asked questions
Can a control room be upgraded while the plant runs?
Yes. Here we replaced one operator group at a time, and operators worked from a temporary position during each swap.
Why regroup the plant before designing the consoles?
The console layout follows the operating model. With fewer operators, grouping the units first meant each person could see all their units and critical alarms from one desk.
What sits at each operator position?
DCS operator and alarm stations, tank gauging, fire and gas, radio, telephony and emergency stops, with the video wall in view.