hmi best practices

Tomorrow’s Automation, Today

A Symposium on Virtualization For the Process & Manufacturing Industries

TR02: HMI Best Practices

Presenter(s):

Mr. Ali Omer(Technical Project Manager )

2

HMI Best Practices

Agenda

The HMI of the Past Common HMI Depictions

Path towards HMI Best Practices

Simple Data Vs. Information

HMI Vs. P&IDs

Importance of Trends

ASM Standards and Guidelines

Examples from a recent Project

3

1

Provided the “Big Picture”

Limited Capability

Many Process Trends

Status “at-a-glance”

AlarmsEquipment Status

Process Values

Human Perception

The HMI of the Past

The “Keyhole View”

High Contrast Screen

Difficult to ascertain Plant KPIs

Contributed to over-alarming

Lost “the Big Picture”

The DCSArrives

5

6

DCS Graphics Introduced – But No Guidelines!

High Contrast Screen

Poor Graphics Encourage Poor Operating Practices

Too Many distracting colours!!

Common, but ineffective process depictions!

Numbers sprinkled on a screen without any philosophy

Inconsistent, improper use of color

No trends

No condition information

Common HMI Depictions

7

Only 10% of the screen is used to show PoorlyPresented numeric data

90% is a just a “pretty picture”

“Improved” Graphic Capability yields even worse practices.

And Even Worse Vendor Examples…

8

Other Industries Do It Better

Although there is a lot of Data and Information crammed into a small space BUT everything is standardized so the pilots don’t have to search for the required Information

Speed

Altitude

Position

Course

Fuel Remaining

Proximity to Ground & Proximity to Rising Terrain

Nearby Airports

GARMIN ® 1000 Avionics System

9

No Overview

No trends

No material balance (FLOW IN and FLOW OUT are on different graphics)

Inconsistent colors andalarms

No condition indication

Essentially just a P&ID segment sprinkled with live values.

Another Bad ExampleTexas City BP HMI

10

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

PLT 310 x109 /L

Answer: Unless you are vet, how can you know?

Data is Not Information: Is Fluffy Sick?

11

After awhile, you might figure it out…


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

What About Now?

12

ABNORMAL VALUES can be seen at a glance.


Test Results RangeIndicator

Low – Normal - High

HCT 31.7% 24.0 – 45.0

HGB 10.2gdl 8.0 – 15.0

MCHC 32.26dl 30.0 - 36.9

WBC 9.2x19L 5.0 – 18.9

GRANS 6.5x19L 2.5 – 12.5

L/M 2.7x19L 1.5 – 7.8

PLT 310x19/L 175 - 500

What About Now?

13

Data is Not Information: Common Depictions

14

Lots of Data

Not Much Information

Poor Presentation

High Mental Workload to Decipher

Cannot grasp what is going on “at-a-glance”

45.1°

48.2°

50.6°

53.8°

54.9°

22.5%

45.1°

48.2°

50.6°

53.8°

54.9°

22.5%

98.2 MPPH221.2 PSI

42.9°

96.2% “XYZ”

DP INH20

12-15 22.8

1-12 16.3

1-15 39.1

77.8 MPPH

60.1°

22.3% “ABC”

Most graphics in the world basically look

like this!

A Column Temperature Profile

The Variable Bar Chart shows a lot more Information as compared to simple Data.

The Line Colours are configured to show deviation alarms – orange for Warnings and red for Alerts!

Just a single glance tells you the complete picture.

Deviation or

absolute numbers

optionally toggled

-0.7

+1.1

+0.8

A good

profile?

Yes, this

one is.

Too hot at

the top, too

cold at the

bottom

20.1

24.2

25.6

27.8

28.9

Optional:

Line color

indicates

abnormality,

alarm is not

yet activated

Analog in Industrial Examples

15

West East

Drive: 232.2 amps

W. Vibration: 2.77 E. Vibration: 3.07

108.2 °F155.2 °F

135.1

psig

190.5 psig

166.1 °F

2.77

MSCFHCooler Oil

155.2 °F

Oil 85.1 psi

55.7 psig

65.1 °F

P&IDs are not HMIs A Poor Paradigm! Typical “P&ID Process Pictorial” – a

low performance, overused paradigm.

Why even make HMIs? – Just take a snapshot of the P&ID and add dynamic values.

HMI is a lot more Information as opposed to a lot more Data

16

Alarm Indicator Appears here with Priority Level and Color

Alarm Range depicted and (for some) shutdown value

Desirable Operating Range shown as dotted lines

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

Buttons for additional functionality

Information is Data in Context Made Useful Analog Indicators with values,

direction, and alarm

Shows Alarm Ranges

Clearly shows ideal Operation Range

RECYCLE COMPRESSOR K43

Show Values Show Trends

S

I

F S. I. D. S. I. I. D. E. W. A O OL P P P T T T T V V M I I

O R R R E E E E I I P L L

W E E E M M M M B B S

S S S P P P P P TE

M

P

OutIn

2

17

18

Current Pressure Alarm Limit Shutdown Actuation

235.2 psig 250 psig 300 psig

Shutdown

-2 HRS

250

300

200

150

100

50

Alarm

Shutdown

-2 HRS

250

300

200

150

100

50

Alarm

Shutdown

-2 HRS

250

300

200

150

100

50

Alarm

The Importance Of Properly Thought Out Trends Figure out what Analog Values

need Trending

Trends greatly reduce the task of decoding the data or even information.

19

Feed FlowP 7.2 mphS 7.0O 34.5 %AUTO

Head Temp P 85.2 degS 85.0O 50.5 %AUTO

Base Temp P 45.1 degS 46.0O 34.5 %AUTO

Level %P 25.6 %S 20.0O 24.5 %AUTO

Bot FlowP 5.1 mphS 4.5O 28.7 %AUTO

RB SteamP 15.1 mphS 15.0O 47.5 %AUTO

#7RHP

COLUMN

Feed MPH 7.2

5.0

9.0

-30-90 -60

Base Temp Deg C 45.6

44.0

48.0

-30-90 -60

Bottom Flow MPH 5.1

2.2

6.5

-60 -30-90

Head Temp Deg C 85.8

83.0

87.0

-60 -30-90

Level % 25.6

12.0

28.0

-30-90 -60

Reboiler Steam MPH 7.2

13.0

17.0

-30-90 -60

TIME

BASE

2 HOURSToggle

OUTPUT

Trends show a lot more! Extremely easy to have a glance

and see overall Plant KPIs without the need to do a lot of number crunching.

Shows Alarm Ranges and ideal Operational Ranges.

20

Other Principles to achieve the Best HMI Design

Poor Vessel

and Line

Depiction !

Crude

Feed

TK-21

CRUDE

FEED

TK-21

Better Vessel

and Line

Depiction

PROD TANK

SCRUBBER

To Scrubber

To Product

Tank

Not a navigation target

Navigation target

Don’t get too fancy

Keep it simple

Avoid 3-D objects – they don’t add any value and increase the load on the overall system

Task With “Traditional”HMI

With High Performance

HMI

Improvement

DetectingAbnormal Situations Before Alarms Occur

10% of the time 48% of the time 5X increase

Success Rate in Handling Abnormal Situation 70% 96%

37% over base case

Time to Complete Abnormal Situation Tasks

18.1 min 10.6 min 41% reduction

The High Performance HMI Advantages

Time after time, poor HMIs are cited as contributing factors to major accidents!

Study by Nova Chemicals and ASM® Consortium

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

21

ASM (Abnormal Situation Management) Standards

22

Select colors to alert operator in abnormal situations

Don’t use fancy, 3D and shinny (Glossy) objects

Use bright saturated colors to indicate abnormal situations only

Data must be presented in such a way that, it reduces Mental Workload

Use Simple, Non-Distracting Elements for PID loops

Devise navigational hierarchy according to process Information

Consider alarms and abnormality in animations

HMI Background Colour has been standardized RGB (192,192,192)

23

ASM (Abnormal Situation Management) Outcome

Real-time awareness

Focus mental resources on controlling the process, not on interacting with the underlying system platform

An HMI design based on an effectively defined display hierarchy, a multiscreen / multi window approach and not a single display / single window approach, simultaneous access to display levels in the display hierarchy,

24

ASM (Abnormal Situation Management) Outcome

Real-time awareness

Focus mental resources on controlling the process, not on interacting with the underlying system platform

An HMI design based on an effectively defined display hierarchy, a multiscreen / multi window approach and not a single display / single window approach, simultaneous access to display levels in the display hierarchy,

Level 1

Process Area Overview Display

Level 2

Process Unit Control Display

Level 2


Level 2


Level 3

Process Unit Detail Display

Level 3


Level 3


Level 4

Process Unit Support Display

Level 4


Level 4


Basic Principles Hierarchy

25

Pumps with Run Indication Sensor:

Wrong Better

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

Not

Running

Running

Wrong Better

STOPPED(Shape is Unfilled

and darker)

RUNNING

(Shape is Filled

and lighter)

Status Depiction (Very Important) Bright Saturated color is used to

indicate ONLY abnormal situations.

A Running Pump or a Stopped Pump is not an abnormal situation.

A Tripped or Interlocked or Faulted Pump is an abnormal situation.

26

Run Plan:

Reactor 1 Actual: Hydrog A Key Performance Indicators

Comp A Comp B Cool CPC CRM LVL Prod: Thionite Cycle Bed Bed Conversion EfficiencyState: Mid-Run Comp A A1 A2

80Agit: ONLocks: CLEAR

Suct Dsch %BalanceIN OUT 500

80.0F

Rate L 12HR70

VIB: OK O

72.0 BRG: OK W Emissions Limit Ratio

2 HR OIL: OK 470 1.0

Locks: CLEAR 2HR

Run Plan:

Reactor 2 Actual: Hydrog B

2Comp A Comp B Cool CPC CRM LVL Prod: CRM-114 Cycle Bed Bed

State: Mid-Run Comp BB1 B2

12HRAgit: ON 0.5

Locks: CLEAR Suct Dsch

Balance Feed System Aux SystemsIN OUT 500

Feed A Feed B Feed C SynG CWT CWP S10 S20068.0

F

Rate L

VIB: OK O

60.0 BRG: OK W2 HR OIL: OK 470

Locks: CLEAR 2 HR Atv 1 Atv 2 Pres %IP PWR VentP VentT MGA

Alarms: P1 P2 P3 P4 ToggleACK 0 1 2 4 List /Summary

Main Reactor Reactor Hydrog HydrogUNACK 0 0 1 1 Menu 1 2 A B

2 071608 08:55:07 RX2 LOW CRM –QUALITY EXCClr T-In T-Out Visc C57D Null-A Jup2 Grok

Trend Feed Aux Menus

Control Sys Sys L2 L3 L4

Reactor 1

Prod: Thionite

State: Mid-Run

Agit: ON Locks:

CLEAR

Run Plan:

Actual:

BalanceIN OUT

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

Prod: CRM-114

State: Mid-Run

Agit: ON Locks:

CLEAR

Balance

Comp A Comp B

60.0

68.0

2 HR

Run Plan:

Actual:

Cool CPC CRM

Rate

IN OUT

Hydrog A

Bed

A1

Bed

A2

Suct Dsch

VIB: OK

BRG: OK

OIL: OK

Locks: CLEAR

Cycle

Comp A

470

500

F

L

O

W

2HR

Hydrog B

Bed

B1

Bed

B2

VIB: OK

BRG: OK

OIL: OK

Locks: CLEAR

Cycle

Comp B

Suct Dsch

500

F

L

O

W

470 2HR

Toggle

List /Summary

Alarms: P1 P2 P3 P4ACK 0 1 2 4UNACK 0 0 1 1

Reactor Hydrog

2 A

Hydrog

B

L3 L4

70

80

%

12HR

Key Performance Indicators

Conversion Efficiency

0.5

1.0

12HR

Emissions Limit Ratio

Feed System

Feed A Feed B Feed C SynG

Atv 1 Atv2 Pres %IP

Clr T-In T-Out Visc

Aux Systems

CWT CWP S10

PWR

C57D Null-A Jup2

S200

VentP VentT MGA

Grok

2

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

LVL

LVL

Level 1 Overview “At-A-Glance Status” Level 1 Overview shows

the complete critical

Plant KPIs as a glance.

Extremely useful for Factory/Plant Managers

27

AUTOO 88.5 %

Main FeedP 76.8 MPHS 76.0

Main Feed MPH80.0

72.0-90 -

60-30 2 Hours

OAUTO

P 11.9 MPHS 12.0

22.3 %

Additive 1

Hours2

Additive 1 MPH14.0

10.0-90 -

60-30

P 4.0 MPHS 4.0O 44.3%AUTO

Additive 2

6.0

2.0

Additive 2 MPH

-90 -60

-30 2 Hours

VENT SYS

Analysis: Purity %

32.0

40.0

-90 -60 -30 2 Hours

Analysis: Inhibitor Concentration %

4.0

6.0

-90 -60 -30 2 Hours

Agitator

ONReactor M5 M5 Pressure

P 98.0 psigS 95.0O 44.3 %AUTO

AUTOO 54.3 %

M5 Level% P 71.0 %S 70.0

52.3 %

5.0 %

Coolant

Flow

AUTO

S 45.0O 54.3%

M5 TempP 45.0 °C

To

Coils

COOLING SYS

92.0 MPHPRODUCT

48.

0

Temperature °C

40.0-90 -

60-30 2 Hours

Product: Thionite State: Mid-

Run

Material Balance

SHUT Reset

DOWNM5

IN OUT

+10%

FREEZE

M5

-10%

ISOLA

TE M5

19707 19301

Calc Diff: 2.1 %Hours: 238.1

Since: 06/02/07

14:00:00

Run

Pl

an

:

Ac

tu

al:Pumps

Needed1

Pump 1

RUNNING

Diagnostics

1-OK 2-

BAD

Pump 2

STOPPED

Main

Menu

- Level 3 -

M5

Interlocks

Product

Recovery

Level 1

Reaction

Overview

M5

Sequence

Overlay

Purge

Rate

Cat.

Activity

Coolant Conversion Reserve

Temp Efficiency Capacity

M5

Startup

Overlay

M4 M6

- Level 3 -

M5 Cooling

System

Feed Components: A - B - C

+/- 5 psi, 2hr

+/- 1 %, 2hr

Trend Feed

Control System

4

Level 2 Process Unit Control Level 2 Process Unit

Control shows the Unit

Control KPIs and Critical Information

Extremely useful for Area Managers

Examples from a Recent Project

29

DC

P O

verv

iew

–Le

vel 1

Ch

iller

Ove

rvie

w –

Leve

l 2

Ch

iller

Co

ntr

ol –

Leve

l 3

Ch

iller

Co

ntr

ol P

aram

ters

Leve

l 4

Dashboard Panels Screen Layout divided in to

side panel and Process screen

On click asset information is populated in Asset Information tab

Trend related to same asset is also generated on same click

Prime KPI of that area is always visible

Question & AnswersThank You for Your Valuable Time

35

Lahore, Pakistan

Headquarters South East Asia

19 Km Main Multan Road

Lahore, Punjab 54660

Pakistan

Phone : + 92 42 111 940 940

Dubai, UAE

Headquarters Middle East And Asia

Office FZS1 BD04, Jebel Ali Free Zone

PO Box 18590, Dubai

United Arab Emirates

Phone: +971 4 88 60 277

Exton, USA

Headquarters Americas

180 Sheree Boulevard, Suite 1400

Exton, PA 19341

United States of America

Phone +1 610 458 8700

Regional Offices and Global Headquarters

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