A high performace HMI

Technology Conference 2013

PAS TECHNOLOGY CONFERENCE

Presented by:

A HIGH PERFORMANCE HMI

#ptc2013 | 1

Hector R. Perez HMI Product Manager


AGENDA HMIs Past and Present

Common but Poor HMI Practices

Justification for HMI Improvement

High Performance HMI Principles and Examples

Proper and Improper Use of Color

Depicting Information Rather Than Raw Data

The Power of Analog

Trend Deficiencies and Improvements

Depicting Alarm Conditions

Display Hierarchy and the Big Picture

The High Performance HMI Development Work Process

Obstacles and Resistance to Improvement

Cost-effective Ways to Make a Major Difference

#ptc2013 | 2


THE HMI OF THE PAST

#ptc2013 | 3

Provided the Big Picture

Limited Capability

Many Process Trends

Status at-a-glance


Traditional Graphics Encourage Poor Operating Practices

#ptc2013 | 4

DCS GRAPHICS INTRODUCED BUT NO GUIDELINES!


DCS GRAPHICS INTRODUCED BUT NO GUIDELINES!

#ptc2013 | 5

Numbers sprinkled on a screen Improper use of color No trends No condition information


Poor HMIs can Kill ! Early, numeric-entry-and-display-based Flight Management Systems were complex to program

FMS input error: American Airlines Flight 965 collides with a mountain in South America.

Korean Airlines flights KAL 902 (in 1978) and KAL 007 (in 1983) were both shot down by the Soviets due to navigation input errors.

Lack of situation awareness is common in fatal aircraft accident reports.

6 #ptc2013 |

POOR HMIS SO WHAT?


Speed Altitude Position Course

Time Enroute Time to next

Waypoint Time to

Destination

Fuel Remaining Proximity to Ground Proximity to Rising

Terrain Nearby Airports

Positions of nearby aircraft

Real-time weather & lightning

Glide Radius

Engine diagnostics Data on Available

Services at Airports

Comm & Nav Frequencies

Instrument Approaches

Lots more!

GARMIN 1000 Avionics System

SITUATION AWARENESS THE UPDATE

#ptc2013 | 7


CLIENT BENEFITS - JUSTIFICATION

Alarm Management

#ptc2013 | 8

Event 2005 - 3

0

5

10

15

20

25

30

35

40

23-May-05

12:00:00

24-May-05

00:00:00

24-May-05

12:00:00

25-May-05

00:00:00

25-May-05

12:00:00

26-May-05

00:00:00

26-May-05

12:00:00

0

20

40

60

80

100

120

140

160

C8 Feed

Alarms / 10 min

Feed Rate vs. Alarm Count Task Improvement

Detecting Abnormal Situations Before Alarms Occur A 5X increase

Success Rate in Handling Abnormal Situation 37% over base case

Time to Complete Abnormal Situation Tasks

41% reduction

Nova estimated $800,000 per year savings on 1 ethylene plant

High Performance HMI


HP HMI Components

#ptc2013 | 9


ALARMS AND SITUATION AWARENESS

#ptc2013 | 10

Alarm Management

Alarm system is reliable

Operators have a high degree of

confidence in the alarm system


YOUR ALARMS ARE NOW UNDER CONTROL

#ptc2013 | 11

Alarm Priority = Critical

Description = Waldo is

on the loose

Critical Alarm = SEVERE consequences requiring IMMEDIATE action


FIND WALDO

#ptc2013 | 12

The system will shut down in seconds 7 6 5 4 3 2 1 0


LETS GO TO GREY SCALE

#ptc2013 | 13


THERE HE IS

#ptc2013 | 14


APPROPRIATE USE OF COLOR

Color is an attention getter.

Use for the abnormal, not the normal.

#ptc2013 | 15


COLOR-BLIND VIEW

~6% of males in the US have certain amount of color blindness

Can you tell which valves are open/closed?

#ptc2013 | 16


I SEE WALDO

Reserve bright colors for abnormal situations.

#ptc2013 | 17

2

Which other measurement is getting close to alarm?


CHECKPOINT

Alarm Management alone is not enough for increased Human Reliability

Graphics that support alarm management efforts are required

Converting graphics to grey scale alone is not enough either

High Performance Objects alone are not enough either

Objective based design is a MUST for High Performance HMI

#ptc2013 | 18


CHECKPOINT






#ptc2013 | 19


ORIGINAL GRAPHIC

#ptc2013 | 20

West East

Drive: 232.2 amps

Cooler

W. Vibration: 2.77 E. Vibration: 3.07

2.77

MSCFH

155.2 F 108.2 F 166.1 F 55.7 psig

135.1

psig

190.5 psig

Oil 155.2 F Oil 85.1 psi

65.1 F

Typical Process Pictorial a low performance overused paradigm


HP HMI?

#ptc2013 | 21

West East

Drive: 232.2 amps

Cooler


2.77

MSCFH

155.2 F 108.2 F 166.1 F55.7 psig

135.1

psig

190.5 psig

Oil 155.2 FOil 85.1 psi

65.1 F

Which PV is about to go into alarm?


CHECKPOINT




Grey graphics contain data NOT information



#ptc2013 | 22


DATA IS NOT INFORMATION

#ptc2013 | 23

Lots of Data Not Much Information Poor Presentation High Mental Workload to Decipher

45.1

48.2

50.6

53.8

54.9

22.5%

42.9

98.2 MPPH

221.2 PSI

96.2% XYZ

22.3% ABC60.1

DP INH20

12-15 22.8

1-12 16.3

1-15 39.1

77.8 MPPH

45.1

48.2

50.6

53.8

54.9

22.5%

42.9

98.2 MPPH

221.2 PSI

96.2% XYZ

22.3% ABC60.1

DP INH20

12-15 22.8

1-12 16.3

1-15 39.1

77.8 MPPH


ANALOG IN INDUSTRIAL EXAMPLES

#ptc2013 | 24

A Column Temperature Profile

Alarm Ranges

20.1

24.2

25.6

27.8

28.9

This one is.

20.1

24.2

25.6

27.8

28.9

18.2

24.0

25.6

29.8

32.9 2

Is this a

good profile?

Too hot at the

bottom, too cold at the top.

Normal

range


HP HMI?

#ptc2013 | 25

West East

Drive: 232.2 amps

Cooler


2.77

MSCFH

155.2 F 108.2 F 166.1 F55.7 psig

135.1

psig

190.5 psig

Oil 155.2 FOil 85.1 psi

65.1 F

Which PV is about to go into alarm?


ANALOG IN INDUSTRIAL EXAMPLES

#ptc2013 | 26

Cool

gpm

RECYCLE COMPRESSOR K43

Alarm Indicator

Desirable Operating Range

Alarm Range

Alarm Range

Show Values Show Trends

Buttons for additional functionality

Suct

psig

Inter

psig

Dsch

psig

Suct

degF

Inter

degF

Dsch

degF

E. Vib

mil

N. Vib

mil

W. Vib

mil

Motor

Amps

Oil

psig

Oil

degF

Interlock Indicator


NOW WHAT DO I DO?

#ptc2013 | 27

Cool

gpm

RECYCLE COMPRESSOR K43

Show Values Show Trends

2

Suct

psig

Inter

psig

Dsch

psig

Suct

degF

Inter

degF

Dsch

degF

E. Vib

mil

N. Vib

mil

W. Vib

mil

Motor

Amps

Oil

psig

Oil

degF

Buttons for additional functionality

Alarm Indicator

Desirable Operating Range

Alarm Range

Alarm Range

Interlock Indicator

TC0001 PVHI

Start Coolilng system


CHECKPOINT






Must embed information in context to expedite actions


#ptc2013 | 28


THE IMPORTANCE OF TRENDS

#ptc2013 | 29

Very Different Situations

Current Pressure

235.2 psigAlarm Setpoint

250 psig

Shutdown Setpoint

300 psig

- 2 HRS

250

300

200

150

100

50

Shutdown Zone

- 2 HRS

Alarm Range

Shutdown Zone

Setpoint Desirable Operating Range

- 2 HRS

250

300

200

150

100

50

Shutdown Zone

- 2 HRS

Alarm Range

Shutdown Zone


- 2 HRS

250

300

200

150

100

50

Shutdown Zone

- 2 HRS

Alarm Range

Shutdown Zone



LEVEL DEPICTION

#ptc2013 | 30

Poor Vessel Level

Indication

Better Vessel Level

Indication

Very Poor Vessel Level

Indication

Trend Vessel Level

Indication

Combination Vessel Level

Indication

Crude Feed TK - 21

2 Hrs 2 Hrs 46.5%

2

0

100


CUSTOM ELEMENTS FOR STARTUPS

#ptc2013 | 31

Always try to clearly depict: Where am I? How am I doing vs. what is good?

Reactor 7 Startup

0

Temperature

Deg C

+30 +60 +90

Feed

Rate

MPH

Additive

Flow

MPH

20

40

60

80

0

5

10

15

20

0

2

4

6

8


ALARM INDICATIONS ON GRAPHICS

#ptc2013 | 32

480.1 psi

No Alarm

480.1 psi

In Alarm

Similar

BadDepictions

480.1

480.1

480.1

480.1 psi 480.1 psi480.1 psi 480.1 psi

Diagnostic Priority

Priority 3 Priority 2 Priority 1

Diagnostic

Priority

Priority 3 Priority 2 Priority 1

480.1 psi 480.1 psi 480.1 psi480.1 psi

2 1

The symbols outlines above are important! Symbols without them would not be as

effective in standing out on a graphic:

Priority 4

DiagnosticPriority 3 Priority 2 Priority 1

480.1 psi 480.1 psi 480.1 psi480.1 psi4 3

2 143

Suppressed

Alarm

480.1 psiS

P

2

SOAUTO

25.6 psi20.084.5 %

Feed Pres

Simple Controller with alarm


STATUS DEPICTION

#ptc2013 | 33

Bright color is used to indicate

abnormal situations only

Pumps with Run Indication Sensor:

Pumps without Run Indication Sensing have a fill matching the background:

Not

Running

Running

Wrong Better

STOPPED

Wrong Better

RUNNING


CHECKPOINT








#ptc2013 | 34


RUNBACK BEFORE (6 8 SCREENS)

#ptc2013 | 35


RUNBACK AFTER

#ptc2013 | 36

"Tag2""Tag2""Tag2"

Gross

MW

562

7.1

Sec air

in.H2O

AUTO7.6

A/F ratio

Pulv Status

D-ONE-ONC-ONF-ON

B-ONH-ONA-ONG-ON

A B

E F

C D

G H

Alarms

Pump Status

A2 CWPON

B2 CWPON

A2 HotON

B2 HotOFF

C2 HotON

SUBFPON

A2BFPON

B2BFPON

Fan Status

A2 CWPON

B2 CWPON

A2 HotON

B2 HotOFF

C2 HotON

SUBFPON

2418

Main

steam

press pisg

1013

Main

steam

temp F

302

Aux steam

psig

-0.5

Furn

in.H2O

0.2

LPT-A

in.hg

3.1

A2

BPFT

10

Drum top-

bot F

301

Turb exp1

mils

1013

Reheat F

0.2

LPT-B

in.hg

3.1

B2

BPFT

301

Turb exp2

mils

Furn

Pres

-0.5

in.H2O

"Tag2""Tag2""Tag2"

Main

Steam

2400

psig

50

Desc1

50

Desc1

LPT-B

3.0

in.hg

"Tag2""Tag2""Tag2"

LPT-A

3.2

in.hg

50

Desc1

50

Desc1

0% 25% 50% 75% 100%Valve

SV-1

SV-2

SV-3

CV-1

CV-2

CV-3

CV-4

RHS-1

RHS-2

IV-1

IV-2

100%

100%

95%

88%

100%

100%

75%

0%

55%

100%

100%

Valve Position

4.9

Econ O2 %

AUTO

Econ O2

5.0

%

Sec air

7.0

in.H2O

"Tag2""Tag2""Tag2"

Air

7400

klbh

50

Desc1 mils

50

Desc1 mils

Blr mast

SP (psi)

2200

Blr mast

output (%)

37

"Tag2""Tag2""Tag2"

Blr mast

PV (psi)

2202

Boiler Master

MANUAL

68

Desc1 mils

Blr mast

SP (psi)

65.0

Blr mast

output (%)

48

"Tag2""Tag2""Tag2"

Blr mast

PV (psi)

65.1

Fuel Master

MANUAL

67.7

Desc1

Blr mast

SP (psi)

65.0

Blr mast

output (%)

48

"Tag2""Tag2""Tag2"

Blr mast

PV (psi)

65.1

A2 BFP

AUTO

67.7

Desc1

Blr mast

SP (psi)

65.0

Blr mast

output (%)

48

"Tag2""Tag2""Tag2"

Blr mast

PV (psi)

65.1

B2 BFP

AUTO

67.7

Desc1

Valve Forced

Open

Valve

controlled

A2 BFP Recirc. Selector

Valve Forced

Open

Valve

controlled

B2 BFP Recirc. Selector

Target Red.

Rate

Gross MW 562

Tricon load rate Very fast

Tricon demand 100.0%

ACS Demand 100.0%

Input new ACS demd 90.0%

Increase loadDecrease load

Coord control

Turbine

Follow

Boiler

Follow

Turbine MASTER MAN

Constant

pressure

Variable

pressure


CHECKPOINT








Hierarchy / Navigation

Situation awareness

The big picture

#ptc2013 | 37


BASIC PRINCIPLES - HIERARCHY

#ptc2013 | 38

Level 1

Process Area

Overview

Display

Level 2

Process Unit

Control Display

Level 2

Process Unit

Control Display

Level 2

Process Unit

Control Display

Note: Possibly More than one

Overview Display available, designed

for significantly different operating

states

Level 3

Process Unit

Detail Display

Level 3

Process Unit

Detail Display

Level 3

Process Unit

Detail Display

Level 4

Process Unit

Support Display

Level 4

Process Unit

Support Display

Level 4

Process Unit

Support Display

For Each Overview Display, Multiple Level 2 Process Unit Detail

Displays

For Each Level 2 Display, Multiple Level 3 Process Unit Detail

Displays

For Each Level 3 Display, Multiple Level 4 Process Unit Support

Displays

Controllers,

Values, Alarms,

Trends, Status

Smaller equipment

groups, Controllers,

Alarms, Values, Trends,

ESD Displays, Equipment

Status

Interlocks, Details,

Diagnostics, First-Outs,

Procedures,

Documentation, Help


EXAMPLES

#ptc2013 | 39


NICKEL MINE OVERVIEW

#ptc2013 | 40


HMI EXAMPLE

#ptc2013 | 41

Reactor 1

Thionite

Mid-Run

ON

CLEAR

Prod:

State:

Agit:

Locks:

Run Plan:

Actual:

IN OUTBalance

Menus

Main

Menu

Feed

Sys

Aux

Sys

Reactor

1

L2

Trend

Control

Comp A Comp B

72.0

80.0

2 HR

Cool CPC CRM

Rate

Reactor 2

CRM-114

Mid-Run

ON

CLEAR

Prod:

State:

Agit:

Locks:

Run Plan:

Actual:

Balance

Comp A Comp B

60.0

68.0

2 HR

Cool CPC CRM

Rate

IN OUT

Hydrog A

Bed

A1

Bed

A2

Suct Dsch

OK

OK

OK

CLEAR

VIB:

BRG:

OIL:

Locks:

Cycle

Comp A

470

500

F

LOW

2 HR

Hydrog B

Bed

B1

Bed

B2

Suct Dsch

OK

OK

OK

CLEAR

VIB:

BRG:

OIL:

Locks:

Cycle

Comp B

470

500

F

LOW

2 HR

Alarms:

ACKUNACK

Toggle

List /Summary

P1

00

P2

10

P3

21

P4

41

Reactor

2

Hydrog

A

Hydrog

B

L3 L4

70

80

%

12 HR

Key Performance Indicators

Conversion Efficiency

0.5

1.0

12 HR

Emissions Limit Ratio

Feed A Feed B Feed C SynG

Feed System Aux Systems

Atv 1 Atv 2 Pres %IP

Clr T-In T-Out Visc

CWT CWP S10

PWR VentP VentT

C57D Null-A Jup2

S200

MGA

Grok2

2

071608 08:55:07 RX2 LOW CRM QUALITY EXC

LVL

LVL


BEFORE

#ptc2013 | 42


BEFORE

#ptc2013 | 43

Technology Conference 2013 #ptc2013 | 44

08-15-2009 14:22:09PULVERIZER OVERVIEW

Coal Flow Trend

Coal

Flow

KLB/HR

2 Hrs1

140

PULV A PULV B PULV C PULV D PULV E PULV F PULV G PULV HL1 OVERVIEW RUNBACK 1 RUNBACK 2

E

F

G

H

75

74

78

45

76

74

75

74

51

50

50

5075

65

55

51

A A A A M A A A

113113

112113

0113

112112

A B C D E F G H

Mill Amps Trend

A A A A M A A A

4243

4244

043

4343

A B C D E F G H

Diff Pres Trend

A A A A M A A A

8.09.8

10.09.5

0.69.8

9.59.0

A B C D E F G H

Pri. Air Flow Trend

A A A A M A A A

204205

204205

0205

204205

A B C D E F G H

A A A A M A A A

A B C D E F G H

H H

75

74

78

77

78

78

75

74

0

0

50

5075

76

55

51

S. Air Flow Trend

A A A A M A A A

204205

204205

0205

204205

A B C D E F G H

A A A A M A A A

A B C D E F G H

Primary Damper

75

74

78

77

78

78

75

74

30

30

50

5075

73

55

51

A A A A M A A A

A B C D E F G H

North Damper South Damper

75

74

78

77

78

78

75

74

40

40

50

5075

65

55

51

C/A Temp Trend

A A A A M A A A

135135

135135

277135

135135

A B C D E F G H

A A A A M A A A

A B C D E F G H

H

75

74

78

77

78

78

75

74

50

50

50

5075

73

55

51

A A A A M A A A

A B C D E F G H

Hot Damper Cold Damper

ON

Pulverizer Status

G

E

C

A

B

D

H

F

ON

ON

ON

ON

ON

ON

ON

Diag

Burn

Maint

A

B

C

D

Diff

PresPSI

2 Hrs0

16

E

F

G

H

A

B

C

D8

OPENOPENSWG Valves

NORMNORMFlm Mnt Mod

OFFOFF

ON

M1Flame

Main

Flame

Igniter

Flame

Fuel Type

Gas -1

Flm Mnt Mod

90 90

30

M2

S

S

OFF

30

ON

SS

L


High Performance HMI Development Work Process

#ptc2013 | 45


THREE PHASES OF AN HMI PROJECT

Step 1: HP HMI Philosophy and Style Guide

Step 2: Assess and benchmark existing graphics

Step 3: Determine specific performance and goal objectives for the control of the process, for all modes of operation

Step 4: Perform task analysis to determine the control manipulations needed to achieve the performance and goal objectives

Step 5a: Design/sketch high performance graphics

Step 5b: Build the designed graphics in the DCS

Step 6: Install, commission, and provide training on the new HMI

Step 7: Control, maintain, and periodically reassess the HMI performance

#ptc2013 | 46

Phase 1

Phase 2

Phase 3


CHALLENGES

Resistance to Change

Graphics are usually designed in-house

Defensive emotional responses

Engineers are often unaware of deficiencies

Operators are used to the old graphics

Costs

#ptc2013 | 47

1990s

June 29, 2007


COST EFFECTIVE WAY TO MAKE A BIG DIFFERENCE

DO ALL LEVEL 2 and LEVEL 1 Graphics first. Implement them, leaving the other existing graphics on the system.

Consider all existing graphics as Level 3. Leave them but alter the navigation paths.

Phase in any new Level 3 and 4 graphics over time as desired

This is inconsistent and non-optimum but will accomplish a lot of the possible improvement.

#ptc2013 | 48


SUMMARY

Traditional HMIs have been cited as contributing factors in industrial accidents

Proper HMIs improve safety, reliability and production performance

Benefits of High Performance HMI:

Brings information in context to the console operators where they work

Provides at a glance situational awareness

Reduces training requirements

Enables proactive intervention

Minimizes shift variation

Minimizes operator fatigue

Increases Human Reliability

Is now practical and achievable

??? ?? ? ?

? ???

#ptc2013 | 49


WRAP-UP

Questions?

Presenter(HPerez@pas.com)

www.pas.com (281) 286-6565

#ptc2013 | 50

A high performace HMI

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