A High Performance HMI

PAS TECHNOLOGY CONFERENCE
A HIGH PERFORMANCE HMI

Presented by: Hector R. Perez
HMI Product Manager
Technology Conference 2013
#ptc2013 | 1
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

Provided the Big Picture
Limited Capability
Many Process Trends
Status at-a-glance
#ptc2013 | 3
DCS GRAPHICS INTRODUCED BUT NO GUIDELINES!
Traditional Graphics Encourage Poor Operating Practices
#ptc2013 | 4
DCS GRAPHICS INTRODUCED BUT NO GUIDELINES!

Numbers
sprinkled on a
screen
Improper use of
color
No trends
No condition
information
#ptc2013 | 5
POOR HMIS SO WHAT?

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.
#ptc2013 | 6
SITUATION AWARENESS THE UPDATE
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
Real-time weather &
lightning
Glide Radius
Engine diagnostics
Data on Available
Services at Airports
Comm & Nav

Frequencies
Instrument
Approaches
Lots more!
#ptc2013 | 7
CLIENT BENEFITS - JUSTIFICATION
Alarm Management
High Performance HMI

Task
Event 2005 - 3
Feed Rate vs. Alarm
Count
40
160
35
140
30
120
25
100
20
80
15
60
10
40
20
0
0
23-May-05 24-May-05 24-May-05 25-May-05 25-May-05 26-May-05 26-May-05
12:00:00
00:00:00 12:00:00
00:00:00 12:00:00
00:00:00 12:00:00
Detecting Abnormal Situations

Before Alarms Occur
C8 Feed
Alarms / 10 min
Success Rate in Handling

Abnormal Situation
Time to Complete Abnormal

Situation Tasks
Improvement
A 5X increase
37% over base case
41% reduction
Nova estimated $800,000 per year

savings on 1 ethylene plant
#ptc2013 | 8
HP HMI Components
#ptc2013 | 9
ALARMS AND SITUATION AWARENESS
Alarm Management
Alarm system is reliable
Operators have a high degree of

confidence in the alarm system
#ptc2013 | 10
YOUR ALARMS ARE NOW UNDER CONTROL
Critical Alarm = SEVERE

consequences requiring
IMMEDIATE action
Alarm Priority = Critical

Description = Waldo is
on the loose
#ptc2013 | 11
FIND WALDO
The system will shut down in
5
6
4
2
3
7
0
1
seconds
#ptc2013 | 12
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.
Which other measurement is getting close to alarm?

#ptc2013 | 17
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
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 Process Pictorial a low performance overused paradigm

#ptc2013 | 20
HP HMI?
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
Which PV is about to go into alarm?
#ptc2013 | 21
CHECKPOINT
Grey graphics contain data NOT information
#ptc2013 | 22
DATA IS NOT INFORMATION
Lots of Data
Not Much Information
Poor Presentation
High Mental Workload
to Decipher
96.2% XYZ
45.1
98.2 MPPH
221.2 PSI
42.9
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
#ptc2013 | 23
ANALOG IN INDUSTRIAL EXAMPLES

A Column Temperature Profile
Alarm Ranges
20.1
20.1
18.2
24.2
24.2
24.0
25.6
25.6
25.6
27.8
27.8
29.8
28.9
28.9
32.9
Normal
range
Is this a
good profile?
This one is.
Too hot at the

bottom, too cold
at the top.
#ptc2013 | 24
HP HMI?
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
Which PV is about to go into alarm?
#ptc2013 | 25
ANALOG IN INDUSTRIAL EXAMPLES

RECYCLE COMPRESSOR K43
Cool
gpm
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
Alarm
Indicator
Alarm Range
Desirable
Operating
Range
Alarm Range
Show Values
Show Trends
Interlock
Indicator
Buttons for additional functionality
#ptc2013 | 26
NOW WHAT DO I DO?

RECYCLE COMPRESSOR K43
Cool
gpm
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
TC0001
PVHI
Start Coolilng system
Alarm
Indicator
Alarm Range
Desirable
Operating
Range
Alarm Range
Show Values
Show Trends
Interlock
Indicator
Buttons for additional functionality
#ptc2013 | 27
CHECKPOINT
Must embed information in context to expedite actions
#ptc2013 | 28
THE IMPORTANCE OF TRENDS

Current Pressure Alarm Setpoint Shutdown Setpoint
235.2 psig
250 psig
300 psig
ShutdownZone
Zone
Shutdown
300
Alarm Range
250
ShutdownZone
Zone
Shutdown
300
Alarm Range
250
200
200
150
150
150
50
Desirable
Operating
Range
Setpoint
-2 HRS
100
50
Desirable
Operating
Range
Setpoint
-2 HRS
Alarm Range
250
200
100
ShutdownZone
Zone
Shutdown
300
100
50
Desirable
Operating
Range
Setpoint
-2 HRS
Very Different Situations
#ptc2013 | 29
LEVEL DEPICTION
2
100
Crude
Feed
TK -21
2 Hrs
Very Poor
Vessel
Level
Indication
Poor
Vessel
Level
Indication
Better
Vessel
Level
Indication
Trend
Vessel
Level
Indication
2 Hrs
46.5%
Combination
Vessel
Level
Indication
#ptc2013 | 30
CUSTOM ELEMENTS FOR STARTUPS

Reactor 7 Startup
Always try to clearly depict:

Where am I?
How am I doing vs.
what is good?
80
60
Temperature
Deg C
40
20
0
20
15
10
Feed
Rate
MPH
5
0
8
6
4
Additive
Flow
MPH
2
0
+30
+60
+90
#ptc2013 | 31
ALARM INDICATIONS ON GRAPHICS

480.1 psi
No Alarm
In Alarm
480.1 psi
480.1
480.1
480.1
Similar
Bad
Depictions
480.1 psi
480.1 psi
480.1 psi
480.1 psi
Diagnostic
Priority
Priority 3
Priority 2
Priority 1
480.1 psi
480.1 psi
480.1 psi
Feed Pres
P 25.6 psi
S 20.0
O 84.5 %
AUTO
2
Simple Controller with alarm
S
Diagnostic
Priority
Priority 3
480.1 psi
480.1 psi
Priority 4
Diagnostic
Priority 3
Priority 2
Priority 1
480.1 psi
Suppressed
Alarm
480.1 psi
480.1 psi
Priority 2
The symbols outlines above are important!

Symbols without them would not be as
effective in standing out on a graphic:
480.1 psi
Priority 1
#ptc2013 | 32
STATUS DEPICTION
Pumps with Run Indication Sensor:
Wrong
Bright color is
used to
indicate
abnormal
situations only
Better
Not
Running
STOPPED
Wrong
Better
Running
RUNNING
Pumps without Run Indication Sensing have a fill matching the background:
#ptc2013 | 33
CHECKPOINT
#ptc2013 | 34
RUNBACK BEFORE (6 8 SCREENS)
#ptc2013 | 35
RUNBACK AFTER
"Tag2"
"Tag2"
"Tag2"
Desc1
Desc1
Target Red.
Rate
Desc1
Desc1
"Tag2"
"Tag2"
"Tag2"
"Tag2"
"Tag2"
"Tag2"
Main
Steam
2400
psig
Gross
MW
562
Desc1 mils
Blr mast
output (%)
37
MAN
6
7
.
7
0%
Turbine
Follow
Boiler
Follow
Constant
pressure
Variable
pressure
Valve Position
25%
50% 75%
100%
100%
100%
95%
CV-1
CV-2
CV-3
CV-4
88%
100%
100%
75%
RHS-1
RHS-2
0%
55%
IV-1
IV-2
100%
100%
Tricon demand
100.0%
ACS Demand
100.0%
Input new ACS demd
90.0%
Decrease load
Increase load
3.1
Valve Forced
Open
Turb exp1
mils
Turb exp2
mils
Blr mast
output (%)
48
B2 BFP Recirc. Selector
Valve
controlled
Main
steam
press pisg
6
7
.
7
Blr mast
SP (psi)
65.0
Valve Forced
Open
Main
steam
temp F
Reheat F
1013
302
Econ O2 %
Sec air
in.H2O
4.9
AUTO
7.1
AUTO
Valve
controlled
Aux steam
psig
Alarms
B C D
F
Fan Status
A2 CWP
A2 Hot
ON
ON
B2 CWP
B2 Hot
ON
OFF
C2 Hot
ON
SUBFP
ON
Pump Status
A2 CWP
A2 Hot
ON
ON
B2 CWP
B2 Hot
ON
OFF
C2 Hot
ON
SUBFP
ON
6
7
.
7
A2 BFP Recirc. Selector
Very fast
Desc1
"Tag2"
"Tag2"
"Tag2"
Blr mast
PV (psi)
65.1
Blr mast
output (%)
48
562
Tricon load rate
Pulv Status
D-ON
B-ON A
E-ON
H-ON
C-ON
A-ON E
F-ON
G-ON
B2 BFP
AUTO
B2
BPFT
"Tag2"
"Tag2"
"Tag2"
Blr mast
SP (psi)
65.0
3.1
Gross MW
Coord control
Desc1
A2 BFP
AUTO
A2
BPFT
Blr mast
PV (psi)
65.1
Blr mast
SP (psi)
65.0
5 5
0 0
Sec air
7.0
in.H2O
Desc1
"Tag2"
"Tag2"
"Tag2"
Blr mast
output (%)
48
Turbine MASTER
SV-1
SV-2
SV-3
Fuel Master
MANUAL
Blr mast
PV (psi)
65.1
6
8
Econ O2
5.0
%
LPT-B
3.0
in.hg
"Tag2"
"Tag2"
"Tag2"
Blr mast
SP (psi)
2200
Valve
Air
7400
klbh
5 5
0 0
Furn
Pres
-0.5
in.H2O
Blr mast
PV (psi)
2202
"Tag2"
"Tag2"
"Tag2"
LPT-A
3.2
in.hg
5 5
0 0
Boiler Master
MANUAL
Desc1
Desc1
mils
mils
A2BFP
ON
B2BFP
ON
301
301
2418
1013
Furn
in.H2O
Drum topbot F
LPT-A
in.hg
LPT-B
in.hg
-0.5
10
0.2
0.2
A/F ratio
7.6
#ptc2013 | 36
CHECKPOINT
Hierarchy / Navigation
Situation awareness
The big picture
#ptc2013 | 37
BASIC PRINCIPLES - HIERARCHY

Level 1
Process Area
Overview
Display
Note: Possibly More than one

Overview Display available, designed
for significantly different operating
states
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
Controllers,
Values, Alarms,
Trends, Status
Smaller equipment
groups, Controllers,
Alarms, Values, Trends,
ESD Displays, Equipment
Status
Interlocks, Details,
Diagnostics, First-Outs,
Procedures,
Documentation, Help
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
#ptc2013 | 38
EXAMPLES
#ptc2013 | 39
NICKEL MINE OVERVIEW
#ptc2013 | 40
HMI EXAMPLE
Reactor 1
Comp A Comp B
Run Plan:
Actual:
Cool
CPC
Key Performance Indicators
Hydrog A
CRM
LVL
Prod:
State:
Agit:
Locks:
Thionite
Mid-Run
ON
CLEAR
Balance
IN
Bed
A1
Cycle
Comp A
Conversion Efficiency
Bed
A2
80
Dsch
Suct
OUT
500
80.0
F
L
O
W
Rate
VIB:
BRG:
OIL:
Locks:
72.0
2 HR
Reactor 2
Run Plan:
Actual:
Cool
CPC
12 HR
70
Emissions Limit Ratio

1.0
470
2 HR
Hydrog B
2
Comp A Comp B
OK
OK
OK
CLEAR
CRM
LVL
Prod:
State:
Agit:
Locks:
CRM-114
Mid-Run
ON
CLEAR
Bed
B1
Cycle
Comp B
Bed
B2
Dsch
Suct
Feed System
Balance
IN
OUT
500
68.0
2 HR
Alarms:
ACK
UNACK
P1 P2 P3 P4
Toggle
2
0
1
4
List /Summary
1
0
0
1
2 071608 08:55:07 RX2 LOW CRM QUALITY EXC
VIB:
BRG:
OIL:
Locks:
OK
OK
OK
CLEAR
Main
Menu
Feed B
Feed C
470
Reactor
1
2 HR
Atv 1
Atv 2
Pres
%IP
Reactor
2
Hydrog
A
T-In
T-Out
Visc
Feed
Sys
SynG
CWT
CWP
S10
S200
PWR
VentP VentT
MGA
C57D
Null-A
Grok
Hydrog
B
Clr
Trend
Control
Aux Systems
Feed A
F
L
O
W
Rate
60.0
12 HR
0.5
Aux
Sys
Jup2
Menus
L2
L3
L4
#ptc2013 | 41
BEFORE
#ptc2013 | 42
BEFORE
#ptc2013 | 43
08-15-2009
PULVERIZER OVERVIEW
Pulverizer Status
Trend
Coal Flow
Burn
Diag Maint
Trend
Diff Pres
Pri. Air Flow
Trend
Primary Damper
A B C D E F G H
A B C D E F G H
A B C D E F G H
A B C D E F G H
A B C D E F G H
A A A A M A A A
A A A A M A A A
A A A A M A A A
A A A A M A A A
A A A A M A A A
A ON
B ON
C ON
D ON
E
F
G
H
Trend
Mill Amps
14:22:09
OFF
ON
ON
ON
113
112
0
112
113 113 113 112
Trend
42
43
42
44
43
43
43
8.0
10.0 0.6
9.5
9.8
9.5
9.8
9.0
204 204
0
204
205 205 205 205
Trend
75 78 76 75 51 50 75 55
74 45 74 74 50 50 65 51
North Damper
South Damper
A B C D E F G H
A B C D E F G H
A B C D E F G H
A B C D E F G H
A B C D E F G H
A B C D E F G H
A A A A M A A A
A A A A M A A A
A A A A M A A A
A A A A M A A A
A A A A M A A A
A A A A M A A A
S. Air Flow
C/A Temp
204 204
0
204
205 205 205 205
75 78 78 75 0 50 75 55 75 78 78 75 30 50 75 55
74 77 78 74 0 50 76 51 74 77 78 74 30 50 73 51
M1
Diff
Pres
PSI
M2
Main
Flame
ON
90
ON
135 135 277 135

135 135 135 135
16
Flame
90
Cold Damper
Hot Damper
75 78 78 75 40 50 75 55 75 78 78 75 50 50 75 55
74 77 78 74 40 50 65 51 74 77 78 74 50 50 73 51
140
Coal
Flow
KLB/HR
A
B
C
D
A
B
C
D
E
F
G
H
E
F
G
H
8
Igniter
Flame
Fuel Type
Gas -1
OFF
30
OFF
30
SWG Valves
OPEN
OPEN
FlmMnt
MntMod
Mod
Flm
NORM
NORM
2 Hrs
L1 OVERVIEW
RUNBACK 1
RUNBACK 2
PULV A
PULV B
PULV C
PULV D
2 Hrs

PULV E
#ptc2013 | 44
PULV F
PULV G
PULV H
High Performance HMI Development Work Process
#ptc2013 | 45
THREE PHASES OF AN HMI PROJECT

Phase 1
Step 1: HP HMI Philosophy and Style Guide
Step 2: Assess and benchmark existing graphics
Phase 2
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
Phase 3
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
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
1990s
June 29, 2007
#ptc2013 | 47
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

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PAS TECHNOLOGY CONFERENCE

A HIGH PERFORMANCE HMI

Technology Conference 2013

Technology Conference 2013

THE HMI OF THE PAST

Technology Conference 2013

DCS GRAPHICS INTRODUCED BUT NO GUIDELINES!

Traditional Graphics Encourage Poor Operating Practices

Technology Conference 2013

DCS GRAPHICS INTRODUCED BUT NO GUIDELINES!

Technology Conference 2013

POOR HMIS SO WHAT?

Korean Airlines flights KAL 902 (in 1978) and KAL

SITUATION AWARENESS THE UPDATE

GARMIN 1000 Avionics System

Technology Conference 2013

Comm & Nav

CLIENT BENEFITS - JUSTIFICATION

High Performance HMI

Detecting Abnormal Situations

Success Rate in Handling

Time to Complete Abnormal

Nova estimated $800,000 per year

Technology Conference 2013

Technology Conference 2013

ALARMS AND SITUATION AWARENESS

Operators have a high degree of

Technology Conference 2013

YOUR ALARMS ARE NOW UNDER CONTROL

Critical Alarm = SEVERE

Alarm Priority = Critical

Technology Conference 2013

Technology Conference 2013

LETS GO TO GREY SCALE

Technology Conference 2013

Technology Conference 2013

APPROPRIATE USE OF COLOR

Technology Conference 2013

Technology Conference 2013

Which other measurement is getting close to alarm?

Technology Conference 2013

Technology Conference 2013

Drive: 232.2 amps

Typical Process Pictorial a low performance overused paradigm

Drive: 232.2 amps

Which PV is about to go into alarm?

Technology Conference 2013

Technology Conference 2013

DATA IS NOT INFORMATION

Technology Conference 2013

ANALOG IN INDUSTRIAL EXAMPLES

Technology Conference 2013

This one is.

Too hot at the

Drive: 232.2 amps

Which PV is about to go into alarm?

Technology Conference 2013

ANALOG IN INDUSTRIAL EXAMPLES

Buttons for additional functionality

Technology Conference 2013

NOW WHAT DO I DO?

Start Coolilng system

Buttons for additional functionality

Technology Conference 2013