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The High

Performance HMI

Insert Photo Here

Proper Graphics
for Operator
Effectiveness
Mark Carrigan
PAS

Rockwell Automation
Process Solutions User Group (PSUG)
November 14-15, 2011
Chicago, IL McCormick Place West
Copyright 2011 Rockwell Automation, Inc. All rights reserved.

Agenda

PAS Overview
The History of HMIs in Industry
High Performance HMI Justification
Common But Ineffective Process Depictions
High Performance Graphic Principles and Elements
High Performance Graphic Hierarchy
The 7-Step High Performance HMI Development Process
Summary

Mark Carrigan

Vice President, Global Business Development at PAS


Roles have included Operations Management
Managing Director, PAS Middle East

The History of HMIs in Industry


High Performance HMI Justification
Common But Ineffective Process Depictions
High Performance Graphic Principles and Elements
High Performance Graphic Hierarchy
The 7-Step High Performance HMI Development Process
Summary

About PAS
Founded in 1993

Privately held Texas Corporation


Process Automation Solutions Provider
110 People in 9 Offices worldwide
Sustainable growth - 300% in 7 years

Business Strategy
Focused on long term growth
Significant investment in R&D; >20% of annual revenue
Ten-year plan on software & technology

Industry Organizations & Strategic Partners


EPRI, ISA, AICHE, NPRA, EMMUA 191
Regional engineering firms

PAS Solutions
Realize the Full Potential of Your People and Automation Systems

Operations Effectiveness
Achieve Superior Operator Performance
and Reduce Vulnerabilities during
abnormal situations and steady state
operations.

Automation Effectiveness
Map the Automation Genome and expose
new possibilities for knowledge retention,
collaboration, and decision support.

Improve Disturbance Rejection

Retain Important Plant Knowledge

Minimize Operator Loading

Provide a Collaboration Platform

Optimize Situational Awareness

Enable Change Tracking/Defect Detection

Enable Accurate Operator Actions

Provide Disaster Recovery

Expand Layers of Protection for Safety

Ensure Accurate Documentation

The High
Performance
HMI:
Insert Photo Here

Proper Graphics
for Operator
Effectiveness

Rockwell Automation
Process Solutions User Group (PSUG)
November 14-15, 2011
Chicago, IL McCormick Place West
Copyright 2011 Rockwell Automation, Inc. All rights reserved.

The HMI of the Past

Provided the Big Picture


Limited Capability
Many Process Trends
Status at-a-glance

Equipment
Status

Process
Values

Human
Perception

Alarms

The DCS Arrives

The Keyhole View


Expensive Screens
Contributed to over-alarming
Lost the Big Picture

Early Group Display


showing 8 sensors

DCS Graphics Introduced But No Guidelines!

Poor Graphics Encourage Poor Operating Practices

Common HMI Depictions


Common, but
ineffective
process
depictions!
Numbers
sprinkled on a
screen
Inconsistent,
improper use of
color
No trends
No condition
information

And Even Worse Vendor Examples

Only 10% of the


screen is used to
show poorlypresented
numeric data,

Improved Graphic Capability yields even worse practices.

90% is a just a
pretty picture

Other Industries Do It Better

GARMIN 1000 Avionics System


 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

 Engine
diagnostics

 Comm & Nav


Frequencies

 Real-time
weather &
lightning

 Data on
Available
Services at
Airports

 Instrument
Approaches

 Glide Radius

 Lots more!

The High Performance HMI


Time after time, poor HMIs are cited as
contributing factors to major accidents!
Study by Nova Chemicals and ASM Consortium
Task

Detecting Abnormal
Situations Before
Alarms Occur
Success Rate in Handling
Abnormal Situation
Time to Complete
Abnormal Situation
Tasks

With Traditional
HMI

With High
Performance
HMI

Improvement

10% of the time

48% of the time

A 5X increase

70%

96%

37% over base


case

18.1 min

10.6 min

41% reduction

$800,000 per year savings anticipated on 1 ethylene plant

Texas City BP HMI a Contributing Factor


Image
taken
from
the CSB
report

No Overview
No trends

No material balance (FLOW IN


and FLOW OUT are on different
graphics)

Inconsistent colors and alarms

No condition indication
Essentially just a P&ID
segment sprinkled with live
values.

Data is Not Information: Is Fluffy Sick?


Blood Tests for Fluffy -1
Test

Results

HCT

31.7%

HGB

10.2 g/dl

MCHC

32.2 6/dl

WBC

9.2 x109 /L

GRANS

6.5 x109 /L

L/M

2.7 x109 /L

Answer: Unless you are vet, how


PLT

310 x109 /L

can you know?

What About Now?


Blood Tests for Fluffy -2
Test

Results

Range

HCT

31.7%

24.0 45.0

HGB

10.2 g/dl

8.0 15.0

MCHC

32.2 6/dl

30.0 - 36.9

WBC

9.2 x109 /L

5.0 18.9

GRANS

6.5 x109 /L

2.5 12.5

L/M

2.7 x109 /L

1.5 7.8

PLT

310 x109 /L

175 - 500

After awhile, you might figure it out

How About Now?


Blood Tests for Fluffy -3
Test

Results

Range

HCT

31.7%

24.0 45.0

HGB

10.2 g/dl

8.0 15.0

MCHC

32.2 6/dl

30.0 - 36.9

WBC

9.2 x109 /L

5.0 18.9

GRANS

6.5 x109 /L

2.5 12.5

L/M

2.7 x109 /L

1.5 7.8

PLT

310 x109 /L

175 - 500

Indicator
Low Normal - High

ABNORMAL VALUES can be seen at a glance.

Data is Not Information: Common Depictions


Most graphics in the
world basically look
like this!

96.2% XYZ
98.2 MPPH
221.2 PSI
42.9

45.1
48.2
50.6
53.8
54.9

22.5%

DP INH20
12-15 22.8
1-12 16.3
1-15 39.1

77.8 MPPH
60.1
22.3% ABC

Lots of Data
Not Much Information
Poor Presentation
High Mental Workload
to Decipher
Cannot grasp what is
going on at-a-glance

Analog in Industrial Examples


Optional:
Line color
indicates
abnormality,
alarm is not
yet activated

20.1
24.2
25.6
27.8
28.9

A good
profile?

Yes, this
one is.

Too hot at
the top, too
cold at the
bottom

+1.1
+0.8

-0.7

Deviation or
absolute numbers
optionally toggled

A Column Temperature Profile

P&IDs are not HMIs: A Poor Paradigm

55.7 psig
65.1

155.2

135.1
psig

108.2

190.5 psig
166.1 F
2.77
MSCFH

Cooler
Oil 155.2 F
Oil 85.1 psi

West

East

W. Vibration: 2.77

E. Vibration: 3.07

Drive: 232.2 amps


Typical P&ID Process Pictorial a low performance, overused paradigm

Information is Data in Context Made Useful


Compressor Status Showing Alarm/Shutdown Limits
RECYCLE COMPRESSOR K43

Alarm Indicator
Appears here
with Priority
Level and
Color
Alarm Range
depicted and
(for some)
shutdown
value
Desirable
Operating
Range shown
as dotted lines

F
L
O
W

S.
P
R
E
S

Show Values

I.
P
R
E
S

D.
P
R
E
S

Show Trends

S.
T
E
M
P

I.
T
E
M
P

I.
T
E
M
P

In

Out

D.
T
E
M
P

E.
V
I
B

W.
V
I
B

A
M
P
S

O
I
L

O
I
L

P
S
I

T
E
M
P

Alarm Range
depicted and
(for some)
shutdown or
interlock
initiator
Buttons for
additional
functionality

Analog is Powerful
Analog Indicators with values, direction, and history
Optional Enhancements for Moving Analog Indicators

Display
Measurement
variability in
the last hour

S.
P
R
E
S

Display
Current 32.1
Value:

Display
Measurement
direction
rolling 10
minutes

S.
P
R
E
S

S.
P
R
E
S

Analog in Industrial Examples


Scrubber Material Balance
Total
Flow
IN

Total
Flow
OUT

Scrubber Material Balance

Accumulated
Difference
1

Total
Flow
IN

Overflow
Warning

Total
Flow
OUT
Overflow
Warning

0.0

0.0

Leak
Warning
0.0

Accumulated
Difference

Leak
Warning
0.0

31.1

27.9

Diff: 3.2
Hours: 22.8
Since: 06/02/07 14:00:00

31.1

Reset
Show Trends

Material Balance Indicators

27.9

Diff:
3.2
Hours: 22.8
Since: 06/02/07 14:00:00

Reset
Show Trends

Analog in Industrial Examples


Scrubber Material Balance
Total
Flow
IN

Total
Flow
OUT
Overflow
Warning

0.0

Accumulated
Difference

Leak
Warning
0.0
31.1

27.9

Diff:
3.2
Hours: 22.8
Since: 06/02/07 14:00:00

Reset
Show Trends

Material Balance Indicator Animation

The Importance Of Trends


Value

Alarm Limit

Needing

Current
Pressure

Shutdown
Actuation

Trend

235.2 psig

250 psig

300 psig

Shutdown

300
250

Shutdown
300

Alarm

Alarm

Alarm

250

250

200

200

200

150

150

150

100

100

100

50

50

50

-2 HRS

Shutdown

300

-2 HRS

-2 HRS

Very Different Situations that only trends can show!

The Importance Of Trends


9.0

Proper
Autoranges

Show
boundaries
of What is
good

5.0

48.0

44.0
6.5

2.2

Feed MPH

-90

7.2

-60

-90

-60

45.6

-90

Feed Flow
P
7.2 mph
7.0
S
O 34.5 %
AUTO

-60
Head Temp
P 85.2 deg
S 85.0
O 50.5 %
AUTO

28.0

-90

5.1

-30
Base Temp
P 45.1 deg
S 46.0
O 34.5 %
AUTO

17.0

-60

85.8

-30

Level %

12.0

-30

Bottom Flow MPH

Head Temp Deg C

83.0

-30

Base Temp Deg C

87.0

25.6

-90

-60

-30

Reboiler Steam MPH

13.0
Level %
P 25.6 %
S 20.0
O 24.5 %
AUTO

-90

-60

Bot Flow
P
5.1 mph
4.5
S
O 28.7 %
AUTO

7.2

TIME
BASE
2 HOURS
Toggle
OUTPUT

-30
RB Steam
P 15.1 mph
S 15.0
O 47.5 %
AUTO

#7
RHP
COLUMN

Custom Elements for Startups


Reactor 7 Startup
80
60

Always try to
clearly depict:

Temperature
Deg C

40
20
65.1

0
20
15
10

How am I
doing vs. what
is good?

Feed
Rate
MPH

5
21.1

0
8
6
4

Where am I?

Additive
Flow
MPH

2
6.9

0
+30

+60

+90

Other Principles
Dont get fancy
Avoid 3-D

Crude
Feed
TK-21

objects

Poor Vessel
and Line
Depiction !

To Scrubber

To Product
Tank

Better Vessel
and Line
Depiction

Not a navigation target

SCRUBBER
CRUDE
FEED
TK-21

Navigation target

PROD TANK

Proper Level Depiction

Crude
Feed
TK-21

2 Hrs

Very Poor
Vessel
Level
Indication

Poor
Vessel
Level
Indication

Better
Vessel
Level
Indication

Trend
Vessel
Level
Indication

Simple, Non-Distracting Element Depiction


SCRUBBER
CRUDE
FEED
TK-21

TK21 Level
P 75.1 %
S 60.0
O 88.5 %
AUTO

FEED SYS
100.0%

SURGE
33.4%

Simple Output % numbers can be


more effective than tiny scales

Tiny
Illegible
Scales

Status Depiction
Pumps with Run Indication Sensor:
Wrong

Better

Not
Running

STOPPED
(Shape is Unfilled
and darker)

Running

Wrong

Better

RUNNING
(Shape is Filled
and lighter)

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

Bright
saturated
color is used
to indicate
abnormal
situations
only

Basic Principles - Hierarchy


HIERARCHY for Displays:

Level 1
Process Area
Overview
Display

Level 1 Process Area Overview


Entire Operator Span of Control.
Single-Glance
Level 2 Process Unit Control
Sub-unit controlled by operator

Level 3 Process Unit Detail


Equipment or controller

Level 4 Process Unit Support


and Diagnostic Displays
Interlocks, ESDs, diagnostic
screens, etc.

Level 2

Level 2

Level 2

Process Unit
Control Display

Process Unit
Control Display

Process Unit
Control Display

Level 3

Level 3

Level 3

Process Unit
Detail Display

Process Unit
Detail Display

Process Unit
Detail Display

Level 4

Level 4

Level 4

Process Unit
Support Display

Process Unit
Support Display

Process Unit
Support Display

Proper Hierarchy minimizes the number of physical


screens and makes for proper navigation

Graphics designed from P&IDs will not accomplish a


proper hierarchy!

Level 1 Overview At-A-Glance Status


Run Plan:
Actual:

Reactor 1
Comp A Comp B

Cool

Hydrog A

CPC

CRM

LVL

Prod: Thionite
State: Mid-Run
Agit: ON
Locks: CLEAR
Balance
IN

Key Performance Indicators


Bed
A1

Cycle
Comp A

Conversion Efficiency

Bed
A2

80

Dsch

Suct

OUT

500

80.0

F
L
O
W

Rate
72.0

VIB:
BRG:
OIL:
Locks:

2 HR

Run Plan:
Actual:

Reactor 2

Cool

Emissions Limit Ratio


1.0

470

2 HR

CPC

CRM

LVL

Prod:
State:
Agit:
Locks:

CRM-114
Mid-Run
ON
CLEAR

Bed
B1

Cycle
Comp B

Bed
B2

IN

Dsch

Suct

OUT

Feed System

500

Feed A

68.0

Rate
60.0

VIB:
BRG:
OIL:
Locks:

2 HR

P1
0
0

P2
1
0

P3
2
1

P4
4
1

Toggle
List /Summary

12 HR

0.5

Balance

Alarms:
ACK
UNACK

12 HR

70

Hydrog B
2

Comp A Comp B

OK
OK
OK
CLEAR

OK
OK
OK
CLEAR

Main
Menu

Reactor
1

Feed
Sys

CWT

CWP

S10

S200

F
L
O
W
470

2 HR

Reactor
2

Hydrog
A

Aux
Sys

Menus
L2

Atv 1

Atv 2

Pres

%IP

PWR

VentP VentT

MGA

Clr

T-In

T-Out

Visc

C57D

Null-A Jup2

Grok

Hydrog
B

2 071608 08:55:07 RX2 LOW CRM QUALITY EXC

Trend
Control

Aux Systems

Feed B Feed C SynG

L3

L4

Level 2 Process Unit Control


Feed Components: A - B - C

Reactor M5

Main Feed
P 76.8 MPH
S 76.0
O 88.5 %
AUTO
80.0

40.0

Product: Thionite

VENT SYS

Agitator
ON

Material Balance

M5 Pressure
P 98.0 psig
S 95.0
O 44.3 %
AUTO

Analysis: Purity %

Mid-Run

State:

SHUT
DOWN
M5

Reset
IN

OUT
+10%

Main Feed MPH


+/- 5 psi, 2hr

32.0
6.0

72.0

-90

-60

-60

FREEZE
M5

+/- 1 %, 2hr

-30 2 Hours

Analysis: Inhibitor Concentration %

-10%

-30 2 Hours

M5 Level %
P 71.0 %
S 70.0
O 54.3 %
AUTO

Additive 1
P 11.9 MPH
S 12.0
O 22.3 %
AUTO
14.0

-90

4.0

-90

Additive 1 MPH

-60

-30 2 Hours

19707

19301
Calc Diff: 2.1 %

ISOLATE
M5

Hours: 238.1
Since: 06/02/07
14:00:00

Run Plan:
Actual:

5.0 %

92.0 MPH

PRODUCT

52.3 %
10.0

-90

-60

-30 2

Hours
Pumps
Pump 1
Diagnostics Pump 2
Needed 1 RUNNING 1-OK 2-BAD STOPPED
4

Additive 2
P
4.0 MPH
4.0
S
O 44.3 %
AUTO
6.0

To
Coils

M5 Temp
P 45.0 C
S 45.0
O 54.3 %
AUTO

Additive 2 MPH

Coolant
Flow

2.0

-90

Main
Menu

-60

-30 2 Hours

Level 1
Reaction
Overview

M4

M6

Purge
Cat.
Rate
Activity
Coolant
Conversion
Reserve
Temp
Efficiency
Capacity

Trend
Control

Feed
System

Product
Recovery

COOLING SYS

M5
Startup
Overlay

48.0

40.0

M5
Sequence
Overlay

Temperature C

-90

- Level 3 M5
Interlocks

-60

-30 2 Hours

- Level 3 M5 Cooling
System

Level 3 Process Unit Detail


20.1 psi

OH

EAST COMP

WEST
COMP
RUNNING

West Compressor

WC Speed
P
90.8 %
S
90.0
O
90.0 %
CAS

90.8

90.0

48.0

111.0

32.0

65.0

IDLE
WEST
COMP

SHUT
DOWN
WEST
COMP

PURGE
WEST
COMP

111.0 C
West Compressor Interlock W-1

1st
Stage

48.0 psi
65.0 C

Initiator
Speed

1 Stg
psi

SHOW / HIDE
VALUES

28.0 C

2nd
Stage

CLR
Out

Winding
Temp

NORMALIZE
SCALE

Flow Demand
P 76.8 MSCFH
S 76.0
O 88.5 %
AUTO

32.0 C
EAST COMP

90.0 psi

CLR
In

20.0 C

CW
44.0 C

2 Stg
psi

48.4 MSCFH

SPEED
CASCADE
IN EFFECT

Value

Overspeed

OK

Or Winding Temp High

OK

Or Vibration High

OK

Or 1 Stg High Pres

OK

Or 2 Stg High Press

OK

Or Suction Pres Low

OK

Or Oil Pres Low

OK

Action
Shut Down
West Comp
AND

Status

Close Inlet &


Outlet Block
Valves
AND
Override East
Comp Speed
to 100%

RECOVERY

50.0

40.0

Main
Menu

West Comp Discharge Temp C

-90

-60

Compression
Level 2

55.0

-30 2 Hours

East
Comp

45.0

Trend
Control

West Comp Flow MSCFH

-90

OH
System

-60

Product
Recovery

95.0

-30 2 Hours

West
Startup
Overlay

West Comp Speed %

85.0

West
Sequence
Overlay

-90

-60

Comp
Cooling
System

-30 2 Hours

- Level 4 Procedures

7 Steps for Creating High Performance Displays


Step 1: Develop a High Performance HMI Philosophy
and Style Guide
Step 2: Assess and benchmark existing graphics against
the HMI Philosophy
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 5: Design and build high performance graphics, using the design
principles in the HMI Philosophy and elements from the Style
Guide, to address the identified tasks
Step 6: Install, commission, and provide training on the new HMI
Step 7: Control, maintain, and periodically reassess the HMI performance

Step 1: Philosophy and Style Guide


High Performance HMI Philosophy Example Table of Contents

Philosophy: the overall principles for


creating the HMI
Philosophy includes information about the
consoles and control room practices.

Style Guide: The DCS and site-specific


collection of graphic elements , indicators,
sub-pictures, trend objects, templates, and
other specific graphic parts to be used
consistently in creating the HMI
Experience has shown that without a
philosophy and style guide, graphics will
usually be created inconsistently and
improperly.

Note: All sub-sections are not shown.


1.0 Introduction
1.1 Purpose and Use of a High Performance HMI Philosophy
1.2 The HMIs Purpose and Functions
1.3 Functional Description of HMI Elements
1.3.1 Display Content
1.3.2 Display Layout
1.3.3 Display Hierarchy
1.3.4 Display Navigation
1.3.5 Alarm Depiction and Alarm Management
2.0 HMI Design Process (considerable detail in this section)
3.0 Purpose and use of an HMI Style Guide and Object Library
3.1

DCS Specificity

3.2

Object Library Contents and Usage

4.0 HMI Performance Monitoring


5.0 HMI Management of Change (MOC)
6.0 Control Room
6.1

Control Room Design Factors

6.2

Control Room Work Practices

6.3

Operator Console Design

6.4

Operator Work Practices

A detailed and comprehensive document!

Step 2: HMI Performance Assessment


A

Evaluate existing HMIs vs. High Performance Principles and


Best Practices
Criteria:

HMI information during normal conditions.


HMI information for effectively monitoring abnormal or upset conditions.
Control room interruptions and distractions by non-essential personnel

Operator tasks during upset or abnormal conditions.


HMI compliance to best practices

Proper Alarm Management

A 100-item questionnaire for use in assessment is


included in The High Performance HMI Handbook

Step 3: Determine Performance and Goal Objectives for


.Process Control
This is rarely done!
Performance and goal objectives should be determined for factors such as:

Process Safety
Efficiency
Equipment health
Production cost
Catalyst life
Environmental
Qaulity

Different operating modes may have different goals (startup, partial rate,
alternative feedstocks, products, etc)
Performance against goals must be depicted on the HMI

Step 3: Determine Performance and Goal Objectives for


Process Control

Example performance and goal objectives:


Example: Refining System
Modes of Operation
Full Rates Product A
Full Rates Product B
End-of-Run Cleanup
Empty - Standby
Mode: Full Rates Product A
Example Performance & Goal Objectives
Overhead Purity >99.2%
Production rate 36,000 lb/hr average on a daily basis
Energy usage <42 MMBTU/Hr
Overhead Pressure between 220 psig and 230 psig
Vent to flare: zero flow
Recycle compressor vibration and bearing temperatures within limits
Overall column tray differential pressure < 62 in.H2O
Sidedraw purity > 88%

Step 4: Task Analysis


For a task analysis, the operator needs:

Information
Controls
Operations
Communications

Performance of
Operator Tasks

Accomplishment
of Performance
Objectives

Typical tasks include:


Controller setpoint and mode manipulation
Digital (on-off) point manipulation (pumps, fin-fan banks, compressor loading,
valve switching, etc.)
Activation and monitoring of advanced control schemes or programmatic controls
Observation of lab results
Direction of outside operators to perform non-automated tasks
Interaction with daily production planning goals & changes
Troubleshooting
Abnormal Situation response

Step 4: Task Analysis


Example output of
Step 4 is used to
determine the graphic
content for each
hierarchy level

Full Rates Product


A Necessary
Level 2 Display
Control Indications
& Manipulations
Overhead Analyzer
Product Purity

Indicator Type
(from Style Guide)

Range

Main Display Trend


#1

Production rate

Main Display Trend


#1
Vertical Scale

Desired purity range is 98%


- 100%. Default time scale
2 hrs.
Scale 30,000 to 40,000
lb/hr.
Good: 40 to 42. Poor: 42 to
50.

Calculated hourly
energy usage in
MMBTU/Hr.
Overhead Pressure

Vertical Scale

Vent to flare

Vertical Scale

Recycle compressor
vibration & bearing
temperatures
Overall Column tray
differential pressure

Vertical scale
multiple module
Main Display Trend
#2

Sidedraw purity > 18%

Main Display Trend


#2

Column Pressure
Controller PC2011-1
Column Level
Controller LC-2011-2
Reflux pump
Start/Stop HS-2011-3
Base pump Start/Stop
HS-2011-4
Recycle compressor

Standard Controller
block
Standard Level
depiction
Standard Digital
Controller
Standard Digital
Controller
Radar plot of

220 psig to 230 psig.


Shutdown at 300.
Zero flow is normal. Scale
to 5,000 lb/hr with autorescale when exceeded
See equipment spec 15-A
for limits.
30 to 70 in.H2O, alarm
above 62. Default time
scale 2 hrs.
10% to 25% range, bad
below 18%. Time scale 2
hrs.

See separate list in the

Step 5: Design the Graphics!


Step 5: Design and build high performance graphics, using the design principles in the HMI
Philosophy And Elements from the Style Guide, to address the identified tasks
Example: Refining System
Modes of Operation
Full Rates Product A
Full Rates Product B
End-of-Run Cleanup
Empty - Standby

Feed Components: A - B - C

Mode: Full Rates Product A


Example Performance & Goal Objectives
Overhead Purity >99.2%
Production rate 36,000 lb/hr average on a daily basis
Energy usage <42 MMBTU/Hr
Overhead Pressure between 220 psig and 230 psig
Vent to flare: zero flow
Recycle compressor vibration and bearing temperatures within limits
Overall column tray differential pressure < 62 in.H2O
Sidedraw purity > 88%
Full Rates Product
A Necessary
Level 2 Display
Control Indications
& Manipulations
Overhead Analyzer
Product Purity
Production rate
Calculated hourly
energy usage in
MMBTU/Hr.
Overhead Pressure

Indicator Type
(from Style Guide)

Range

Main Display Trend


#1

Desired purity range is 98%


- 100%. Default time scale
2 hrs.
Scale 30,000 to 40,000
lb/hr.
Good: 40 to 42. Poor: 42 to
50.

Main Display Trend


#1
Vertical Scale
Vertical Scale

Vent to flare

Vertical Scale

Recycle compressor
vibration & bearing
temperatures
Overall Column tray
differential pressure

Vertical scale
multiple module
Main Display Trend
#2

Sidedraw purity > 18%

Main Display Trend


#2

Column Pressure
Controller PC2011-1
Column Level
Controller LC-2011-2
Reflux pump
Start/Stop HS-2011-3
Base pump Start/Stop
HS-2011-4
Recycle compressor
function
Sidedraw sep. level

Standard Controller
block
Standard Level
depiction
Standard Digital
Controller
Standard Digital
Controller
Radar plot of
multiple items
Std. Level depiction

Reactor M5

Main Feed
P 76.8 MPH
S 76.0
O 88.5 %
AUTO
80.0

30 to 70 in.H2O, alarm
above 62. Default time
scale 2 hrs.
10% to 25% range, bad
below 18%. Time scale 2
hrs.

See separate list in the


compressor specification

Analysis: Purity %

Mid-Run

State:

Material Balance

M5 Pressure
P 98.0 psig
S 95.0
O 44.3 %
AUTO

SHUT
DOWN
M5

Reset
IN

OUT
+10%

Main Feed MPH


+/- 5 psi, 2hr

32.0
6.0

72.0

-90

-60

-90

-60

FREEZE
M5

+/- 1 %, 2hr

-30 2 Hours

Analysis: Inhibitor Concentration %

-10%

-30 2 Hours

M5 Level %
P 71.0 %
S 70.0
O 54.3 %
AUTO

Additive 1
P 11.9 MPH
S 12.0
O 22.3 %
AUTO
14.0

220 psig to 230 psig.


Shutdown at 300.
Zero flow is normal. Scale
to 5,000 lb/hr with autorescale when exceeded
See equipment spec 15-A
for limits.

40.0

Product: Thionite

VENT SYS

Agitator
ON

4.0

-90

Additive 1 MPH

-60

-30 2 Hours

19707

19301
Calc Diff: 2.1 %

ISOLATE
M5

Hours: 238.1
Since: 06/02/07
14:00:00

Run Plan:
Actual:

5.0 %

92.0 MPH

PRODUCT

52.3 %
10.0

-90

-60

-30 2

Hours
Pumps
Pump 1
Diagnostics Pump 2
Needed 1 RUNNING 1-OK 2-BAD STOPPED
4

Additive 2
P
4.0 MPH
4.0
S
O 44.3 %
AUTO
6.0

To
Coils

M5 Temp
P 45.0 C
S 45.0
O 54.3 %
AUTO

Additive 2 MPH

Coolant
Flow

2.0

-90

Main
Menu

-60

Coolant
Temp

-30 2 Hours

Level 1
Reaction
Overview

M4

M6

Trend
Control

Purge
Cat.
Rate
Activity
Conversion
Reserve
Efficiency
Capacity

Feed
System

Product
Recovery

COOLING SYS

M5
Startup
Overlay

This sounds easy.

48.0

40.0

M5
Sequence
Overlay

Temperature C

-90

- Level 3 M5
Interlocks

-60

-30 2 Hours

- Level 3 M5 Cooling
System

Step 6: Install, Commission, And Provide Training On The New


Displays

Implementation and training issues can


be complex - thoroughly covered in
the HMI Handbook
Some example topics for operator
training:

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DCS operating procedures (refresher)


Aspects of the High Performance HMI Philosophy relevant to operations
The reasons the HMI was changed and the expected benefits
Features of the DCS and HMI alarm presentation, annunciation, and management
Navigation in the High Performance HMI
Use of trends
The HMIs progressive hierarchy
Graphics for specific situations (such as rate changes, product changes, and shutdowns)
Changes from the old graphics and proper use of the new graphics

Step 7: Control, Maintain, and Periodically Reassess


the HMI Performance

Operator Surveys
On-going HMI suggestion system
Specific HMI performance review after production upsets,
incidents, and accidents

Summary

Poor HMIs have been cited as contributing factors to incidents and accidents
Poor HMI practices are common
Proper HMIs are an important success factor
A High Performance HMI is practical and achievable.

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