Performance HMI
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
About PAS
Founded in 1993
Business Strategy
Focused on long term growth
Significant investment in R&D; >20% of annual revenue
Ten-year plan on software & technology
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.
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.
Equipment
Status
Process
Values
Human
Perception
Alarms
90% is a just a
pretty picture
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
Real-time
weather &
lightning
Data on
Available
Services at
Airports
Instrument
Approaches
Glide Radius
Lots more!
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
A 5X increase
70%
96%
18.1 min
10.6 min
41% reduction
No Overview
No trends
No condition indication
Essentially just a P&ID
segment sprinkled with live
values.
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
310 x109 /L
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
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
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
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
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
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
Total
Flow
OUT
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
27.9
Diff:
3.2
Hours: 22.8
Since: 06/02/07 14:00:00
Reset
Show Trends
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
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
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
83.0
-30
87.0
25.6
-90
-60
-30
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
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
SCRUBBER
CRUDE
FEED
TK-21
Navigation target
PROD TANK
Crude
Feed
TK-21
2 Hrs
Very Poor
Vessel
Level
Indication
Poor
Vessel
Level
Indication
Better
Vessel
Level
Indication
Trend
Vessel
Level
Indication
TK21 Level
P 75.1 %
S 60.0
O 88.5 %
AUTO
FEED SYS
100.0%
SURGE
33.4%
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
Level 1
Process Area
Overview
Display
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
Reactor 1
Comp A Comp B
Cool
Hydrog A
CPC
CRM
LVL
Prod: Thionite
State: Mid-Run
Agit: ON
Locks: CLEAR
Balance
IN
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
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
Trend
Control
Aux Systems
L3
L4
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%
32.0
6.0
72.0
-90
-60
-60
FREEZE
M5
+/- 1 %, 2hr
-30 2 Hours
-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
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
OK
Or Vibration High
OK
OK
OK
OK
OK
Action
Shut Down
West Comp
AND
Status
RECOVERY
50.0
40.0
Main
Menu
-90
-60
Compression
Level 2
55.0
-30 2 Hours
East
Comp
45.0
Trend
Control
-90
OH
System
-60
Product
Recovery
95.0
-30 2 Hours
West
Startup
Overlay
85.0
West
Sequence
Overlay
-90
-60
Comp
Cooling
System
-30 2 Hours
- Level 4 Procedures
DCS Specificity
3.2
6.2
6.3
6.4
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
Information
Controls
Operations
Communications
Performance of
Operator Tasks
Accomplishment
of Performance
Objectives
Indicator Type
(from Style Guide)
Range
Production rate
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
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
Feed Components: A - B - C
Indicator Type
(from Style Guide)
Range
Vent to flare
Vertical Scale
Recycle compressor
vibration & bearing
temperatures
Overall Column tray
differential pressure
Vertical scale
multiple module
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.
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%
32.0
6.0
72.0
-90
-60
-90
-60
FREEZE
M5
+/- 1 %, 2hr
-30 2 Hours
-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
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
48.0
40.0
M5
Sequence
Overlay
Temperature C
-90
- Level 3 M5
Interlocks
-60
-30 2 Hours
- Level 3 M5 Cooling
System
?
?
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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