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Human Machine Interfaces (HMIs)

Objectives
When you have completed study of this chapter, you will be able to,
• Understand HMI related Ergonomic Factors.
• Understand HMI Configuration
• Understand HMI Design & Layout
• Understand HMI Alarm & Reporting.

4.1 Introduction

As you are aware most of the SCADA terminals are remotely placed. To effectively access data
and perform control functions for these remote terminals; we need equally well-designed Human
Machine Interfaces.

As you are aware, HMI is ‘an Operator station using which a Operator can interact
effectively & efficiently with a process’. That’s why it is called ‘Human Machine Interface’.

HMI design is very important because a good HMI design can help in the long run it can
definitely improve the productivity and reliability of the overall system.

4.2 HMI related ergonomic factors

4.2.1  Overview

The main reason for considering HMI related ergonomic requirements is to simplify and improve
the operator interaction with the process; thus to improve the productivity and reliability of the
overall system indirectly.

4.2.2 Ergonomic factors

The objective of this discussion is to provide a useful set of guidelines for the design of an
effective operator display system. The approach should be to ensure that the displays are as easy

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to read and understand as possible.

This in turn reduces the decoding process in the human brain to a minimal level and maximizes
the decision-making processes of the brain as per Figure 4.1.

This ensures that the operator can react quickly and effectively without having to work out where
the problem is.

Figure 4.1
Ergonomic versus non-ergonomic representation of data

If we check the ergonomic factors associated with HMI station then we can divide it into two
areas,

• Related with HMI hardware

• Related with HMI Display

This is because of the fact that, HMI display is one area where operator has to pay attention.
Similarly it’s the HMI hardware through which he has to interact with HMI station and to the
process.

So we will have first look at typical HMI configuration.

4.3 HMI configuration

A typical HMI configuration consists of following hardware:

• One or more operator displays (which may be of the touch screen type)
• Industrial (or Mylar) type keyboards which have audible or tactile feedback
• Operator panels consisting of highlighted keys to bring up predefined graphic displays
• Printers (one for alarms and one for reports)
• Alarm buzzers (or external sirens)

(A useful addition although possibly expensive option is a video copier for reproducing the
operator screens in color.)

HMI can be broadly classified in two main categories,

1. PC based HMI station

2. Graphic Operator Displays

PC based HMI station:

The HMI station is installed on a computer (usually a Industrial grade) with HMI software
package and other software utilities. This HMI station has other hardware components mentioned

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above.
Typical PC based HMI station looks like similar to computer station hardware wise. Only
difference lies in the display contents.

Graphic Operator Displays:

These operator displays are generally small graphic display unit with onboard special function
keys as well as regular keys and communication port.
They are basically used for providing operator access to small terminals or small process control
units.

Figure 4.2
Typical Graphic operator panel (Courtesy: SIEMENS)

The unit can be programmed as per process requirement and used thereafter for monitoring &
controlling process. But when we take a look at features offered by it; then it offers comparatively
less features to that of PC based HMI station.

Apart from array of features offered basic functionality of both systems remains the same. In both
cases, the hardware ergonomic requirements will be more or less the same.
For example, the keyboard has to be suitable as per the operating environment. Mylar or
industrial keyboard is advisable.

Similarly if it is indoor application then one can opt for touch screen HMI display; but if it is
dusty environment then one has to think before going for touch screen HMI display.

HMI hardware such as display should be located at position from where operator can comfortably
see the screens with proper viewing angle.

In case of keyboard keys assignment for HMI’s one has to take care to put the critical keys
assignment aside than the normally operated keys. Ergonomic requirements of HMI display
(screens, Alarms, etc.); we will check simultaneously as we will discuss the further sections.

4.4 HMI design & layout

HMI Design and layout also has to be done keeping in mind the ergonomic factor. This will not
only simplify the handling of process by operator; but also make it more effective and reliable.

HMI layout decides how easily & effectively operator can navigate through HMI screens with
reference to the process control philosophy requirement.

And a good individual screen design makes HMI operator more conversant with plant sections
and related controls.

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4.4.1  HMI layout          

The organization of displays should be done in a clear and logical way to allow the operator to
quickly and effectively identify the information of interest. The architecture of displays is to have
a progressive decrease in scope of the displays and a progressive increase in detail as the operator
looks for some specific information (and is proceeding down the hierarchy of displays).

Displays should be organized into three layers:

The primary level
This is an overview level and it should be reached directly from the function keys on the keypad.
The secondary level
This consists of a number of displays, associated with that of the primary level. It should be able
to be accessed directly from the primary level displays.
The tertiary level
It gives more details on certain secondary level, displays further.

The suggested layout of the displays is given in Figure 4.3 below.

Figure 4.3
Display hierarchy

With more than three levels, the display becomes unduly complex and this should be avoided
unless absolutely necessary. There are various associated displays such as trend displays and help
screens. Zoom boxes are useful features, which provide more detail on a specific area of the
schematic.

The various graphic screens that are available are:

• Free form graphic screens
These screens provide a screen format that can be created by the users, using whatever
layout and symbols they can create. It can be best constructed by the operators (with
assistance from the engineer). They offer the designer complete flexibility in the layout of
the information.
• Operating group displays
Here a standard set of symbols is used to create displays as required. These provide the
data in a standard presentation format.

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• Trend displays
These displays occupy part or the entire screen depending on the configuration. They
provide trends on the data of analog values.
• Alarm displays
These log the current alarms for the system.

It has been shown that operators consult and use overview type schematics at least ten times more
often than secondary and tertiary schematics. It is thus imperative that as much effort as possible
goes into the correct design of such displays. The operators should be consulted as much as
possible in the design of these screens to make them as useful as possible.
Overview displays have to cover a large amount of the system and it is thus important to
eliminate any part of the display, which does not convey information to the operator. This would
mean that equipment outlines and flow lines are not put into overview schematics.
Secondary and tertiary displays are consulted less and probably require more information than
that of the live updates. Outlines of equipment and text messages should be de-emphasized by
using low intensity colors.
An icon should be designed to indicate clearly the area associated with a given schematic or
operation. This allows the operator to quickly work out which area the current display is referring
to.

4.4.2 HMI design          

As we have seen above, HMI screens are divided into following types,
• Graphic window
• Trend Window
• Alarm window

We will discuss individual design aspects of these HMI screens. But before doing that note
following general guidelines; which should be followed while designing any HMI window.

There are generally two conflicting demands made on the design of screens:
• Reduce the complexity of the screen
• Try and keep all the displays associated with a given function to a minimum.
There are a number of effective ways in which to design appropriate operator screens.

A few techniques to bear in mind are:

1) Signal to noise ratio
If the signal (on any display) is defined as the information the operator is looking for and noise is
information the operator does not require, it is clear that the purpose of a particular screen should
be carefully defined so as to maximize live data relating to the current function, and minimization
of irrelevant data (and detailed graphic layouts of shape of vessels and piping etc).

2) Color and symbols

Color chart guidelines should be followed where possible. Composite symbols and flags should
be devised for devices with different states such as on/off/tripped/unavailable etc, for a pump.
Flow lines and tanks should be dark blue when inactive and red (for example) when active.
Following fig.4.4 shows such example of Pump composite symbol.

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Figure 4.4
Display hierarchy

Patterns should be used where possible to reduce the complexity and clutter of the display. Do not
exceed 100 mm by 100 mm areas with patterns, as it is difficult for the operator to comprehend
areas larger than this on one screen.
High priority areas on the screen should be highlighted with high intensity and bright colors. Dull
unattractive colors should be used for unimportant items. Alternatively, unimportant items should
be left off the screen.
Outlines of equipment items should be simple; a life-like representation is not needed and may in
fact clutter the screen unnecessarily.
Outlines should be clearly differentiated from each other; even if this requires a certain amount of
exaggeration.
Do not fill outlines up unless absolutely necessary (and then only with dull colors).

Graphic window
Generally you will find a graphic window is divided in following parts,

• Top portion for display of latest alarms and events.

• Middle portion for Graphics of process section.

• Bottom portion for keys providing navigation to other screens.

To give you actual idea about the layout, following figure 4.5 shows actual HMI station graphic
screen image,

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Figure 4.5
Graphic Display Layout (Courtesy: ABB)

• Top Area Display

It is also a standard type of window section; which is used to show the latest alarm and event.
Similarly it is used for showing critical parameters of process and other standard function keys.

• Middle Area Display

This is freely configurable display area;; which is used to show status of the process section and
incorporate controls associated with it. Operator can go in further details of equipment by clicking
on equipment and opening pop-up windows.

• Bottom Area Display

This is freely configurable display area; which is used for defining special soft keys. The soft
keys are used for user to switch from one screen to other screen or for navigation.

Trend window
Trend window can be arranged in complete screen or small pop-window depending on the
requirement. It provides current as well as archive data logging pf analogue in the form of trends.

Following figure 4.6 shows one such image of trend screen.

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Figure 4.6
Trend Screen Layout (Courtesy: ABB)

Along with the trends of process parameters; it offers different tools such as zoom in, zoom out,
ruler, X-Y plot, etc. to facilitate analysis of different process parameters. These features are really
very useful from operation and maintenance point of view.

Trends tag has to be defined along with scan time or logging time; which is freely configurable. It
is one of the important criteria while selecting HMI software; since different softwares has
different range of logging time.

Alarm window
All process related or system related alarms are logged as and when happen and displayed in
Alarm screen area.
Normally alarms are defined group wise which are decided as per process sections.
Following figure 4.7 shows one such image of Alarm screen.

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Figure 4.7
Alarm Screen Layout (Courtesy: ABB)

Alarm screen shows an alarm along with other necessary information such as date & time when it
occurred, acknowledged, reset. This feature enables user to check alarms history of past few days.

Alarm processing is an important part of the operator station. Error codes identifying the faults
are normally included with the description of the failed device.

No other part of the operator display has as much impact on the health of the plant (and that of the
operator). The alarm function should be viewed as an integral part of the operator interface and
not as a stand-alone feature.

4.5 HMI alarm & reporting

Alarm processing is an important part of the operator station. Error codes identifying the
faults are normally included with the description of the failed device.
Figure 4.8 gives a view on the actions that occur on an alarm being activated.

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Figure 4.8
Alarm actions in an operator display

Another approach as opposed to the pure screen listing of alarms is to have an associated
enunciator panel (situated next to the operator display) with illuminated pushbuttons. Each
pushbutton would indicate the area from which the alarms originate and also when depressed
would cause the appropriate schematic to appear on the operator display.

Only four alarm priorities should be implemented. These are:

• High priority
Alarms that warn of dangerous conditions that could cause a shutdown of a major activity.
• Medium priority
Alarms that should be acted on as quickly as possible; but will not cause a shutdown.
• Low priority
Alarms that should be dealt with when time permits.
• Event only
Represents, Statistical or technical information. No annunciator sounds for these.

Following color scheme is advisable for showing above type of alarms in HMI,

Suggested colors for alarms could be:

   
RED HIGH PRIORITY
   
MAGENTA MEDIUM PRIORITY
   
YELLOW LOW

The color scheme may be different as per the individual industry standards or customer
requirement.

The limiting of the number of types of alarms is to keep the system straightforward and with easy

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interpretation of the alarms. Higher priority alarms should be louder; lower pitched and have a
higher pulse frequency than the lower priority alarms. Alarms are classified as unacknowledged
(and flashing on the screen) until the operator acknowledges them via the keyboard. They then
become an accepted alarm. One weakness in many alarm systems is the occurrence of trivial
alarms, which irritate and confuse the operator. Typical trivial alarms are summarized in the table
below:

Table 4.1
List of trivial alarms

Type of Symptom Remedy

Alarm
Consequential Repetitive alarms caused by a Inhibit the alarm until the
condition that the operator is condition is remedied
aware of
Out of service Alarms are caused by Inhibit the alarms
equipment not in service
No action Operator unable to rectify the Delete the alarm from the
alarms problem system
Equipment Regular equipment Ensure the alarms are
changes maintenance etc causes alarms suppressed for this period by
added alarm logic
Minor event Operator constantly being Delete alarm and replace with
notified about trivial events event recording
Multiple Many alarms triggered by one Use first up alarming to reduce
fault the alarm information
Cycling Signal close to alarm level Expand the range of signal
moves the alarm in and out of before moving into alarm
alarm condition
Instrument drift Drift of instrument causes alarm Ensure there is tight control on
the calibration of instruments

It is important to continuously audit, maintain, and improve on the alarm system through analysis
and review with the operators on the performance of the system.
For every alarm the following should be documented:

• Type of alarm
• Alarmed tag
• Description of tag
• Reasons for alarm
• Relationship to related alarms (consequential relationships)
• Description of the logic in the generation of the alarm
• Possible causes of the alarm
Action steps should be taken to remedy the alarm situation.

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