Unidad 5a - How To Improve Plant Operations Through Better HMI Graphics

VZ02 – How to Improve Plant
Operations Through Better HMI

Graphics
PUBLIC
“Design is so simple, that is
why it is so complicated”
Paul Rand
PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 3

BP Amoco, Texas City (2005)

BP Amoco, Texas City (2005)

What is HMI?
User interface to monitor and control machine or system

Problems
Information overload
• Large amounts of process data

• Ineffective displays
• Inappropriate use of graphics

Human cognitive limitations
• Memory
• Attention
Environment:
• Vision Input
Rehearsal
Attention Short-term Long-term
Sensory
Memory Retrieval Memory
Memory
Rehearsal Loop
Recall
Texaco Pembroke (1994)
Well designed HMI

• Help prevent shutdowns
• Improve safety
• Improve efficiency

Texaco Pembroke (1994)
Shutdowns and accidents, costly Well-designed HMI

• Injuries • Help prevent shutdowns and accidents
• Downtime • Help improve safety
• Productivity • Help increase efficiency
• Insurance
High ROI for well-designed HMI

Solutions
Better HMI
how
what
where most
who projects
start here!
The user
• Roles, functions, expertise

• Focus on primary user
• Don’t forget others
• Goals and Tasks

• Observation + interviews
• Identify information + context
• Human limitations + capabilities

Understanding Users
What are their goals and tasks?
• Determine different types of users

• Observe users
• Performing actual work
• Insights not gained through conversation
• Interview users
• What can’t be observed
• Goal is to identify:
• Goals
• Tasks
• Information & Controls

Task Analysis
Analyze the user research and document
Goal Goal … Safety, Production rate, Efficiency, Run length, Equipment health,
Environmental, Production cost, Quality, Catalyst life, Reliability,
etc.
Tasks Tasks … Maintain production rate at …, Balance run hours on pumps, Keep
production costs below…, etc.
Sub-tasks Sub-tasks … Activate advanced control, rotate pumps, review lab results,
contact field operator to close manual valve, etc.
Steps Steps … Open block valve, start pump A, validate flow, stop pump B, close
block valve, etc.
Controls &
Information
Controls &
Information
…
Mental model

Persona

The environment
• Technology
• Screen type
• Equipment
• PPE
• Workstation
• Cabinet
• Audience
• Conditions
• Lighting
• Noise
Workstation (Console) Design
Ideally part of larger control room design (ISO 11064)
• Should consider the needs of the operators

• Furniture design (might include annunciators, radios,
phones, etc.)
• Building is often designed around those operator needs/tasks

• Acoustics, lighting, colors, etc.
• Refer to ANSI/HFES 100-2007 and ISO 11064 for further

details on console and control room design
• Where appropriate, utilize architectural firms and other

consultants for effective overall environment
• Operator console design is important, but must work
will within the larger control room space

Design of Workstation
• Display Philosophy
• What requires dedicated display space?

• Is there information that is always critical to view? Trends Trends
• Do I need to reserve a window to display the alarm list?
Level 1
• Do I need to reserve windows for trends?
Alarm List
• Does anything need to be in a large overhead display? Level
4
Level 2 Level 3
• Plan on at least one area dedicated for Level 2 to be used Face Face
plate plate
• Where will Level 3 and 4 displays be shown?

The strategy
Building upon findings from User and Environment
• Documentation
• Organization
• Layout

Documentation
• Philosophy
• Best practices
• Lifecycle
• Style Guide
• Key principles
• All aspects covered
• Highly detailed
• New standards
• Rockwell Automation Process HMI Style Guide (PROCES-WP023A-EN-P)

Documentation
• Philosophy
• Best practices
• Lifecycle
• Style Guide
• Key principles
• All aspects covered
• Highly detailed
• New standards
• Rockwell Automation Process HMI Style Guide (PROCES-WP023A-EN-P)

Organization
• User’s Goals + Tasks
• Match User’s Mental Model
• Related Information Together
• Navigation Paradigm
• Progressive Disclosure (4 levels)

Hierarchy
Level 1 Overview Display

Provide an overview of the
operator’s entire span of
responsibility.
Operator’s primary operating

Level 2 Process Unit Control Display display. Normal operations, routine
changes and monitoring.
Non-routine operations. Provide

Level 3 Process Unit Detail Display sufficient information to facilitate
process diagnostics.
Interlocks, Diagnostics, Help and

Level 4 Process Unit Support Display Documentation. Usually
faceplates or popups.

Multi-Level, Multi-View Displays
Shown on a big More detailed
screen monitor all Level 1 display. Used for
the time. higher level control.
Level 2 Level 2
Level 3 Level 3 Level 3 Level 3 Level 3 Level 3
Level 4 Level 4 Level 4

Traditional P&ID Style
Diagnostic level or task-oriented display used to operate every
display. Used to show aspect of the process.
troubleshooting data. (optional)

Navigation
A four-level display hierarchy may not be ideal for your process
Must be quick
• Minimize number of clicks/selections and amount of typing
• Navigation by typing display name may be helpful in some scenarios but should not be necessary
Must be logical
Must be consistent
ISA suggests a maximum of four levels is recommended

Level 1
• Assimilate Quickly
• Performance Indication
Obvious
• Highlights Key Info
• High-level
• Easy Access to
More Detail

Level 2
• Main Displays
• Info + Control
• Create First
• User’s Mental Model
• Easy Access to
Other Displays

Level 3
• Detailed View of:

• Sub-Units
• Equipment
• Components
• Troubleshooting

Level 4
• More Detail
• Procedures
• Popups
• Faceplates

Navigation
• Main
• Related
• Consistency

Navigation
Multi-window (typically multi-monitor also) Workstation
Level 1
Level 1
Recommended
3 4
Level 2
Level 2
Best!
Not
2 5 2
Level 3
Level 3
1 6
Level 4 A B 1 3
Level 4 A B
Level 1
2
Trends Trends
Level 2
Level 1
Good
3
Level 3 Alarm List
1 4
aaaaa bbbbb ccccc ddddd eeeee fffff ggggg hhhhh kkkkk nnnnn
Level 4 A B Level
4
Level 2 Level 3
Face Face
Source: ASM Consortium Guidelines plate plate

Don’t do this… Instead, do this…

Alarm Management is Critical!
https://www.exida.com/Alarm-Management

Layout
• Not P&IDs
• Match Mental
Model
• Remove What’s
Unnecessary

Layout
• Not P&IDs
• Match Mental
Model
• Remove What’s
Unnecessary

Don’t do this Instead, do this…

The Tactics
Execution based on your strategy
• Limitations
• Tools

Limitations
Environment:
Input
Rehearsal
Attention Short-term Long-term
Sensory
Memory Retrieval Memory
Memory
Rehearsal Loop
Recall

90823049823049750987234985710982134098709
874230598710982134098720987509817230948721
30984709824980982345908298098172309487123
4980249806745687098347346098343458093809
45334630854890097370981391582488131983498
0139852340968702943867092

90823049823049750987234985710982134098709
874230598710982134098720987509817230948721
30984709824980982345908298098172309487123
4980249806745687098347346098343458093809
45334630854890097370981391582488131983498
0139852340968702943867092

90823049823049750987234985710982134098709
874230598710982134098720987509817230948721
30984709824980982345908298098172309487123
4980249806745687098347346098343458093809
45334630854892097370981391582488121983498
0139852340968702943867092

Pre-attentive attributes

Pre-attentive attributes, continued

“You know you have reached perfection of
design not when you have nothing more to
add, but when you have nothing more to take
away”
Antoine de Saint-Exupéry

The Tools
• Element
• Location
• Size
• Label
• Color

“Data is not information”
Cliff Stoll

Element
Information is data… in context… made useful

48.0
Temp Acidity DHEA

Blood Pressure CSF Cholesterol 40.0

Temp Blood Pressure Cholesterol

Vertical gauge
User-defined name
Tag name
Scale
Alarm threshold Tick marks
Normal operating range

Current value
Setpoint
Numeric display
Engineering unit

Trend Name Units
Setpoint High limit Current value
Scale
Pen marker
Grid
Time span
Low limit
Sparkline
Name
Value
High limit
Current value
Units Setpoint Low limit

Icons
Urgent High Medium Low

Objects

Location

Location

Location

Size
Primary
Secondary
Tertiary

Label

Color

Color

Color

AI: Opacity

AI: Aesthetics

Color
Don’t do this… Instead, do this…

Color

• Element
• Location
• Size
• Label
• Color

• Element
• Location
• Size
• Label
• Color

PlantPAx® FactoryTalk® View SE

Studio 5000 View Designer®

FactoryTalk® Cloud

References
References
• ISA 101, Human-Machine Interfaces
• ASM Consortium Guidelines – ISBN 978-1514203859
• Effective Console Operator HMI Design: Second Edition (2015)
• PROCES-WP016A-EN-E. Human Machine Interfaces for Distributed Control Systems:

Creating and Maintaining an Effective User Environment with Efficient Graphics.
• PROCES-WP023A-EN-P. Rockwell Automation Process HMI Style Guide.
• “High Performance HMI Handbook,” Hollifield et al
• “Information Dashboard Design,” Stephen Few
• American Fuel & Petrochemical Manufacturers AM-15-07
• Operator Situation Awareness & Delivering ASM-Compliant High
Performance HMIs: Failure Modes and Success Factors
• Rockwell Automation® Library of Process Objects

• Available from the Rockwell Automation Knowledgebase
• KBAid 62682 – Rockwell Automation Library of Process Objects
• Rockwell Automation TechED™ 2016 Presentation: TS03: The Operator-Centered HMI: A Practical Approach
• Rockwell Automation TechED™ 2019 Presentation: PR09: How to Implement an Effective Operator Workstation
Packet
https://drive.google.com/file/d/1S5OU1ZZGukVlP75Zz7o5yi73XExfL5K-
/view?usp=sharing
Thank you
www.rockwellautomation.com

Unidad 5a - How To Improve Plant Operations Through Better HMI Graphics

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Unidad 5a - How To Improve Plant Operations Through Better HMI Graphics

Uploaded by

Copyright:

Available Formats

VZ02 – How to Improve Plant

Operations Through Better HMI

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 3

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 8

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 9

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 10

• Large amounts of process data

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 12

Well designed HMI

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 15

Shutdowns and accidents, costly Well-designed HMI

High ROI for well-designed HMI

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 16

• Roles, functions, expertise

• Goals and Tasks

• Human limitations + capabilities

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 19

What are their goals and tasks?

• Determine different types of users

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 20

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 22

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 23

• Should consider the needs of the operators

• Building is often designed around those operator needs/tasks

• Refer to ANSI/HFES 100-2007 and ISO 11064 for further

• Where appropriate, utilize architectural firms and other

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 25

• What requires dedicated display space?

• Where will Level 3 and 4 displays be shown?

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 26

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 27

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 28

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 29

• User’s Goals + Tasks

• Match User’s Mental Model

• Related Information Together

• Progressive Disclosure (4 levels)

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 30

Level 1 Overview Display

Operator’s primary operating

Non-routine operations. Provide

Interlocks, Diagnostics, Help and

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 31

Level 3 Level 3 Level 3 Level 3 Level 3 Level 3

Level 4 Level 4 Level 4

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 32

ISA suggests a maximum of four levels is recommended

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 33

• Highlights Key Info

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 34

• User’s Mental Model

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 35

• Detailed View of:

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 36

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 37

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 38

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 39

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 40

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 41

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 42

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 43

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 44

PUBLIC • Copyright ©2021 Rockwell Automation, Inc. 47