The High

Performance HMI

Proper Graphics
for Operator
Insert Photo Here 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 Automation Effectiveness

Achieve Superior Operator Performance Map the Automation Genome and expose
and Reduce Vulnerabilities during new possibilities for knowledge retention,
abnormal situations and steady state collaboration, and decision support.
operations.

• 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” Equipment Process Human
Status Values Perception Alarms
• Limited Capability
• Many Process Trends
• Status “at-a-glance”
 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 poorly-
presented
numeric data,

90% is a just a
“Improved” Graphic Capability yields even worse practices.
“pretty picture”
 Other Industries Do It Better

GARMIN ® 1000 Avionics System

Speed
Time
Fuel Remaining
Positions of
Engine
Comm & Nav

Enroute nearby aircraft diagnostics Frequencies

Altitude
Proximity to

Time to next Ground
Real-time
Data on
Instrument

Position Waypoint weather & Available Approaches

Proximity to lightning Services at

Course
Time to Rising Terrain
Lots more!
Airports
Destination
Glide Radius

Nearby Airports
 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 With “Traditional” With High Improvement
HMI Performance
HMI
Detecting Abnormal
Situations Before 10% of the time 48% of the time A 5X increase
Alarms Occur
Success Rate in Handling
37% over base
Abnormal Situation 70% 96%
case

Time to Complete
Abnormal Situation 18.1 min 10.6 min 41% reduction
Tasks

$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 material balance (FLOW IN • No condition indication

• No trends and FLOW OUT are on different
graphics)
• Essentially just a P&ID
segment sprinkled with live
• Inconsistent colors and alarms 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 Indicator
Low – Normal - High
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

ABNORMAL VALUES can be seen at a glance.

 Data is Not Information: Common Depictions

Most graphics in the

96.2% “XYZ” world basically look
45.1° like this!
98.2 MPPH
221.2 PSI 48.2°
42.9° 50.6° DP INH20 • Lots of Data
12-15 22.8
53.8° • Not Much Information
1-12 16.3
54.9° 1-15 39.1 • Poor Presentation
• High Mental Workload
to Decipher
77.8 MPPH
22.5% 60.1° • Cannot grasp what is
22.3% “ABC” going on “at-a-glance”
 Analog in Industrial Examples

20.1 Optional: +1.1

Line color
24.2 +0.8
indicates
25.6 abnormality,
27.8 alarm is not
28.9 yet activated -0.7

A good Yes, this Too hot at Deviation or

profile? one is. the top, too absolute numbers
cold at the optionally toggled
bottom
A Column Temperature Profile
 P&IDs are not HMIs: A Poor Paradigm

190.5 psig
55.7 psig 155.2 °F 108.2 °F 166.1 °F
65.1 °F 2.77
135.1 Cooler MSCFH
psig
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

Alarm Indicator
RECYCLE COMPRESSOR K43 Appears here
2 with Priority
Level and
Color
Alarm Range
depicted and
(for some)
shutdown
value
Desirable
Operating
Range shown
as dotted lines

Alarm Range
depicted and
F S. I. D. S. I. I. D. E. W. A O O (for some)
L P P P T T T T V V M I I shutdown or
O R R R E E E E I I P L L interlock
W E E E M M M M B B S
initiator
S S S P P P P P T
In Out S E Buttons for
I M additional
Show Values Show Trends P
functionality
Analog is Powerful
Analog Indicators with values, direction, and history

Optional Enhancements for Moving Analog Indicators

Display Display
Measurement Current 32.1 Display
variability in Value: Measurement
the last hour direction –
rolling 10
minutes

S. S. S.
P P P
R R R
E E E
S S S
Analog in Industrial Examples
Scrubber Material Balance Scrubber Material Balance

Total Total Accumulated Total Total

Flow Flow Difference Flow Flow
IN OUT 1 1
IN OUT
Overflow Overflow
Warning Warning

0.0 0.0
Accumulated
Difference

Leak Leak
Warning Warning
0.0 0.0
31.1 27.9 31.1 27.9

Diff: 3.2 Reset Diff: 3.2 Reset

Hours: 22.8 Hours: 22.8
Since: 06/02/07 14:00:00 Since: 06/02/07 14:00:00
Show Trends Show Trends

Material Balance Indicators

Analog in Industrial Examples

Scrubber Material Balance

Total Total
Flow Flow
IN 1 OUT
Overflow
Warning

0.0
Accumulated
Difference

Leak
Warning
0.0
31.1 27.9

Diff: 3.2 Reset

Hours: 22.8
Since: 06/02/07 14:00:00
Show Trends

Material Balance Indicator Animation

 The Importance Of Trends

Value Current Alarm Limit Shutdown

Needing Pressure Actuation

Trend 235.2 psig 250 psig 300 psig

Shutdown Shutdown Shutdown

300 300 300
Alarm Alarm Alarm
250 250 250

200 200 200

150 150 150

100 100 100

50 50 50
-2 HRS
-2 HRS -2 HRS

Very Different Situations that only trends can show!

 The Importance Of Trends

9.0 Feed MPH 7.2 87.0 Head Temp Deg C 85.8

• Proper
Auto-
ranges
5.0 83.0
-90 -60 -30 -90 -60 -30
• Show
boundaries 48.0 Base Temp Deg C 45.6 28.0 Level % 25.6
of “What is
good”
TIME
BASE
44.0 12.0 2 HOURS
-90 -60 -30 -90 -60 -30
Toggle
OUTPUT
6.5 Bottom Flow MPH 5.1 17.0 Reboiler Steam MPH 7.2

2.2 13.0
-90 -60 -30 -90 -60 -30

Feed Flow Head Temp Base Temp Level % Bot Flow RB Steam
P 7.2 mph P 85.2 deg P 45.1 deg P 25.6 % P 5.1 mph P 15.1 mph #7
S 7.0 S 85.0 S 46.0 S 20.0 S 4.5 S 15.0 RHP
O 34.5 % O 50.5 % O 34.5 % O 24.5 % O 28.7 % O 47.5 % COLUMN
AUTO AUTO AUTO AUTO AUTO AUTO
Custom Elements for Startups
Reactor 7 Startup

80 Temperature Always try to

60 Deg C
clearly depict:
40
20 “Where am I?”
65.1
0
20
Feed
“How am I
15 Rate doing vs. what
MPH
10 is “good?”
5
21.1
0
8
Additive
6 Flow
4 MPH

2
6.9
0
+30 +60 +90
 Other Principles

• Don’t get fancy

• Avoid 3-D
Crude
objects Feed
To Scrubber
TK-21

Poor Vessel To Product

and Line Tank
Depiction !

Better Vessel
and Line Not a navigation target
Depiction

SCRUBBER

CRUDE Navigation target

FEED
TK-21
PROD TANK
 Proper Level Depiction

Crude
Feed
TK-21

2 Hrs

Very Poor Poor Better Trend

Vessel Vessel Vessel Vessel
Level Level Level Level
Indication Indication Indication Indication
Simple, Non-Distracting Element Depiction

SCRUBBER

CRUDE TK21 Level

FEED P 75.1 %
TK-21 S 60.0
O 88.5 %
AUTO

FEED SYS
100.0%

SURGE
33.4%

Tiny
Simple Output % numbers can be Illegible
Scales
more effective than tiny scales
 Status Depiction
Pumps with Run Indication Sensor:
Wrong Better

Not
Running
STOPPED Bright
(Shape is Unfilled
and darker) saturated
color is used
to indicate
Running
abnormal
RUNNING
(Shape is Filled
situations
Wrong Better
and lighter) only
Pumps without Run Indication Sensing have a fill matching the background:
 Basic Principles - Hierarchy

HIERARCHY for Displays: Level 1

Process Area

• Level 1 – Process Area Overview Overview

Display
• Entire Operator Span of Control.
“Single-Glance” Level 2 Level 2 Level 2
Process Unit Process Unit Process Unit
Control Display Control Display Control Display
• Level 2 – Process Unit Control
• Sub-unit controlled by operator
Level 3 Level 3 Level 3
• Level 3 – Process Unit Detail Process Unit Process Unit Process Unit

• Equipment or controller Detail Display Detail Display Detail Display

• Level 4 – Process Unit Support

Level 4 Level 4 Level 4
and Diagnostic Displays Process Unit Process Unit Process Unit
• Interlocks, ESDs, diagnostic Support Display Support Display Support Display

screens, etc.
• 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:
Reactor 1 Actual: Hydrog A Key Performance Indicators
Comp A Comp B Cool CPC CRM LVL Prod: Thionite Cycle Bed Bed Conversion Efficiency
State: Mid-Run Comp A
A1 A2
Agit: ON 80
Locks: CLEAR
Suct Dsch %
Balance
IN OUT
500
80.0
F
Rate L
70 12 HR
VIB: OK O
W Emissions Limit Ratio
72.0 BRG: OK
2 HR OIL: OK 470 1.0
Locks: CLEAR 2 HR

Run Plan:
Reactor 2 Actual:
Hydrog B
2 Bed Bed
Comp A Comp B Cool CPC CRM LVL Prod: CRM-114 Cycle
B1 B2
State: Mid-Run Comp B 12 HR
Agit: ON 0.5
Locks: CLEAR Suct Dsch
Balance
IN OUT
Feed System Aux Systems
500
Feed A Feed B Feed C SynG CWT CWP S10 S200
68.0
F
Rate L
VIB: OK O
BRG: OK W
60.0
2 HR OIL: OK 470 Atv 1 Atv 2 Pres %IP PWR VentP VentT MGA
Locks: CLEAR 2 HR

Alarms: P1 P2 P3 P4 Toggle
ACK 0 1 2 4 Main Reactor Reactor Hydrog Hydrog
List /Summary
UNACK 0 0 1 1 Menu 1 2 A B
2 071608 08:55:07 RX2 LOW CRM –QUALITY EXC
Clr T-In T-Out Visc C57D Null-A Jup2 Grok

Trend Feed Aux Menus

Control Sys Sys
L2 L3 L4
 Level 2 Process Unit Control
Feed Components: A - B - C VENT SYS Product: Thionite State: Mid-Run
Agitator
ON Material Balance
Main Feed Reactor M5 M5 Pressure
P 76.8 MPH P 98.0 psig
S 76.0 S 95.0 SHUT Reset
40.0 Analysis: Purity %
O 88.5 % O 44.3 % DOWN
AUTO AUTO M5 IN OUT
Main Feed MPH +10%
80.0
+/- 5 psi, 2hr
FREEZE
32.0 +/- 1 %, 2hr M5
-90 -60 -30 2 Hours

6.0 Analysis: Inhibitor Concentration %

72.0 -10%
-90 -60 -30 2 Hours
M5 Level % 19707 19301
Additive 1 P 71.0 % ISOLATE
S 70.0 Calc Diff: 2.1 %
P 11.9 MPH M5 Hours: 238.1
S 12.0 O 54.3 %
O 22.3 % AUTO Since: 06/02/07
AUTO 14:00:00
4.0
-90 -60 -30 2 Hours
Additive 1 MPH 5.0 % Run Plan:
14.0
Actual:

92.0 MPH
PRODUCT
52.3 %
10.0 Hours
-90 -60 -30 2 Pumps Pump 1 Diagnostics Pump 2
Additive 2 Needed 1 RUNNING 1-OK 2-BAD STOPPED
P 4.0 MPH 4
S 4.0
O 44.3 % To
AUTO M5 Temp
Coils 48.0 Temperature °C
P 45.0 °C
6.0 Additive 2 MPH S 45.0
O 54.3 %
AUTO

Coolant Purge Cat.

Flow Rate Activity
40.0
Coolant Conversion Reserve COOLING SYS -90 -60 -30 2 Hours
2.0 Temp Efficiency Capacity
-90 -60 -30 2 Hours

Level 1 M5 M5 - Level 3 - - Level 3 -

Main Trend Feed Product
Reaction M4 M6 Startup Sequence M5 M5 Cooling
Menu Control System Recovery
Overview Overlay Overlay Interlocks System
 Level 3 Process Unit Detail
20.1 psi
OH EAST COMP West Compressor

WC Speed
WEST P 90.8 % SHUT
COMP S 90.0 IDLE PURGE DOWN
O 90.0 % WEST WEST
RUNNING CAS WEST
90.8 111.0 COMP COMP
90.0 32.0 COMP
48.0 65.0
111.0 °C

West Compressor Interlock W-1

48.0 psi
Initiator Value Action Status
65.0 °C Speed 1 Stg 2 Stg CLR CLR Winding
1st Overspeed Shut Down
psi psi In Out Temp OK
Stage West Comp
20.0 °C Or Winding Temp High OK AND
CW SHOW / HIDE NORMALIZE Or Vibration High OK Close Inlet &
VALUES SCALE
28.0 °C Or 1 Stg High Pres Outlet Block
44.0 °C 2nd OK
Valves
Stage 32.0 °C Flow Demand SPEED Or 2 Stg High Press OK AND
P 76.8 MSCFH
EAST COMP S 76.0 CASCADE Or Suction Pres Low OK Override East
O 88.5 % IN EFFECT
AUTO Or Oil Pres Low Comp Speed
90.0 psi 48.4 MSCFH OK
to 100%
RECOVERY

50.0 West Comp Discharge Temp °C 55.0 West Comp Flow MSCFH 95.0 West Comp Speed %

40.0 45.0 85.0

-90 -60 -30 2 Hours -90 -60 -30 2 Hours -90 -60 -30 2 Hours

West West Comp

Main Compression East Trend OH Product - Level 4 -
Startup Sequence Cooling
Menu Level 2 Comp Control System Recovery Procedures
Overlay Overlay System
 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 Note: All sub-sections are not shown.
1.0 Introduction
creating the HMI 1.1 Purpose and Use of a High Performance HMI Philosophy
– Philosophy includes information about the 1.2 The HMIs Purpose and Functions
consoles and control room practices. 1.3 Functional Description of HMI Elements
1.3.1 Display Content
• Style Guide: The DCS and site-specific 1.3.2 Display Layout
collection of graphic elements , indicators, 1.3.3 Display Hierarchy
sub-pictures, trend objects, templates, and 1.3.4 Display Navigation
1.3.5 Alarm Depiction and Alarm Management
other specific graphic parts to be used 2.0 HMI Design Process (considerable detail in this section)
consistently in creating the HMI 3.0 Purpose and use of an HMI Style Guide and Object Library
3.1 DCS Specificity
• Experience has shown that without a 3.2 Object Library Contents and Usage
philosophy and style guide, graphics will 4.0 HMI Performance Monitoring
5.0 HMI Management of Change (MOC)
usually be created inconsistently and 6.0 Control Room
improperly. 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

Evaluate existing HMIs vs. High Performance Principles and

A
Best Practices
Criteria:
– HMI information during normal conditions.
B
– HMI information for effectively monitoring abnormal or upset conditions.
– Control room interruptions and distractions by non-essential personnel
C – Operator tasks during upset or abnormal conditions.
– HMI compliance to best practices

D – Proper Alarm Management

F 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 Performance of Accomplishment
Operator Tasks of Performance
– Controls Objectives

– Operations
– Communications
• 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
Full Rates Product Indicator Type Range
Example output of “A” – Necessary
Level 2 Display
(from Style Guide)

Step 4 is used to Control Indications

& Manipulations
determine the graphic Overhead Analyzer
Product Purity
Main Display Trend
#1
Desired purity range is 98%
- 100%. Default time scale
content for each 2 hrs.
Production rate Main Display Trend Scale 30,000 to 40,000
hierarchy level #1 lb/hr.
Calculated hourly Vertical Scale Good: 40 to 42. Poor: 42 to
energy usage in 50.
MMBTU/Hr.
Overhead Pressure Vertical Scale 220 psig to 230 psig.
Shutdown at 300.
Vent to flare Vertical Scale Zero flow is normal. Scale
to 5,000 lb/hr with auto-
rescale when exceeded
Recycle compressor Vertical scale See equipment spec 15-A
vibration & bearing multiple module for limits.
temperatures
Overall Column tray Main Display Trend 30 to 70 in.H2O, alarm
differential pressure #2 above 62. Default time
scale 2 hrs.
Sidedraw purity > 18% Main Display Trend 10% to 25% range, bad
#2 below 18%. Time scale 2
hrs.
Column Pressure Standard Controller
Controller PC2011-1 block
Column Level Standard Level
Controller LC-2011-2 depiction
Reflux pump Standard Digital
Start/Stop HS-2011-3 Controller
Base pump Start/Stop Standard Digital
HS-2011-4 Controller
Recycle compressor Radar plot of 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”
Feed Components: A - B - C VENT SYS Product: Thionite State: Mid-Run
Full Rates Product “B” Agitator
End-of-Run Cleanup ON Material Balance
Main Feed Reactor M5 M5 Pressure
P 76.8 MPH P 98.0 psig
Empty - Standby S 76.0 Analysis: Purity % S 95.0 SHUT Reset
O 88.5 % 40.0 O 44.3 % DOWN
AUTO AUTO M5 IN OUT
Mode: Full Rates Product “A” – Main Feed MPH +10%
Example Performance & Goal Objectives 80.0
Overhead Purity >99.2% +/- 5 psi, 2hr
Production rate 36,000 lb/hr average on a daily basis FREEZE
32.0 -90 -60 -30 2 Hours +/- 1 %, 2hr M5
Energy usage <42 MMBTU/Hr
Overhead Pressure between 220 psig and 230 psig Analysis: Inhibitor Concentration %
6.0 -10%
Vent to flare: zero flow 72.0
-90 -60 -30 2 Hours M5 Level %
Recycle compressor vibration and bearing temperatures within limits 19707 19301
Additive 1 P 71.0 % ISOLATE
Overall column tray differential pressure < 62 in.H2O S 70.0 Calc Diff: 2.1 %
P 11.9 MPH M5 Hours: 238.1
S 12.0 O 54.3 %
Sidedraw purity > 88% AUTO Since: 06/02/07
O 22.3 %
AUTO 14:00:00
Full Rates Product Indicator Type Range 4.0 -90 -60 -30 2 Hours
Additive 1 MPH 5.0 % Run Plan:
“A” – Necessary (from Style Guide) 14.0
Level 2 Display Actual:
Control Indications
& Manipulations 92.0 MPH
Overhead Analyzer Main Display Trend Desired purity range is 98% PRODUCT
Product Purity #1 - 100%. Default time scale 52.3 %
2 hrs. Hours
Production rate Main Display Trend Scale 30,000 to 40,000 10.0
-90 -60 -30 2 Pumps Pump 1 Diagnostics Pump 2
#1 lb/hr.
Calculated hourly Vertical Scale Good: 40 to 42. Poor: 42 to Additive 2 Needed 1 RUNNING 1-OK 2-BAD STOPPED
energy usage in 50. P 4.0 MPH 4
S 4.0
MMBTU/Hr. O 44.3 %
Overhead Pressure Vertical Scale 220 psig to 230 psig. To
AUTO M5 Temp
Shutdown at 300. Coils 48.0 Temperature °C
P 45.0 °C
Vent to flare Vertical Scale Zero flow is normal. Scale 6.0 Additive 2 MPH S 45.0
to 5,000 lb/hr with auto- O 54.3 %
rescale when exceeded AUTO
Recycle compressor Vertical scale See equipment spec 15-A
vibration & bearing multiple module for limits. Coolant Purge Cat.
temperatures Flow Rate Activity
Overall Column tray Main Display Trend 30 to 70 in.H2O, alarm 40.0
Coolant Conversion Reserve COOLING SYS -90 -60 -30 2 Hours
differential pressure #2 above 62. Default time 2.0 Temp Efficiency Capacity
-90 -60 -30 2 Hours
scale 2 hrs.
Sidedraw purity > 18% Main Display Trend 10% to 25% range, bad
#2 below 18%. Time scale 2 Level 1 M5 M5 - Level 3 - - Level 3 -
hrs. Main Trend Feed Product
Reaction M4 M6 Startup Sequence M5 M5 Cooling
Column Pressure Standard Controller Menu Control System Recovery
Controller PC2011-1 block Overview Overlay Overlay Interlocks System
Column Level Standard Level
Controller LC-2011-2 depiction
Reflux pump Standard Digital
Start/Stop HS-2011-3 Controller
Base pump Start/Stop Standard Digital
HS-2011-4
Recycle compressor
function
Sidedraw sep. level
Controller
Radar plot of
multiple items
Std. Level depiction
See separate list in the
compressor specification
This sounds easy….
 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:
– 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 HMI’s 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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