High Performance HMI · PPA Symposium Time for new paradigms High Performance HMI Alain Wullaert December 8th, 2011

PPA SymposiumTime for new paradigms

High Performance HMI

Alain WullaertDecember 8th, 2011

Operations Effectiveness

• Operations Effectiveness – The achievement of optimal operator performance and reduced vulnerabilities during abnormal situations and steady state operations.

• Operations Effectiveness is achieved by expanding a plant’s inherent layers of protection. – Improve disturbance rejection– Minimize operator loading – Increase situation awareness– Enable accurate operator actions

Layers of Protection

1. PID Control – First line of defense • Steady state operation

• Transition handling

• Minor disturbances rejection

Minor Upset

Steady State

PID Control

Layers of Protection1. PID Control – First line of defense

• Steady state operation



2. Operator Intervention • Operator HMI

• Alarms

Minor Upset

Major Upset

Steady State

PID ControlOperator Intervention

Operator Support Systems

Often fail the operator when they are needed the most!

Layers of Protection

1. PID Control – First line of defense • Steady state operation



2. Operator Intervention • Operator HMI

• Alarms

• Dependent upon severity of event & operator competence

3. Safety Instrumented System• Last automated line of defense

• Safe unit shutdown

• No immediate point of return

Minor Upset

Major Upset

Steady State

PID ControlOperator Intervention

Shutdown

SIS

Failure to build the layers of protection result in lost

production, reduced profits, near misses, incidents,

unplanned shutdowns, and, in extreme cases, accidents.

Operator HMI’s Past…

• Provided the “Big Picture”• Limited Capability• Many Trends• Status “at-a-glance”

Graphics Introduced – but no guidelines!

Traditional Graphics Encourage Poor Operating Practices

“Traditional” GraphicsNumbers “sprinkled”on a screen

Improper use of color

No trends

No condition information

Traditional Graphics Encourage Poor Operating Practices

High Performance HMI Justification

© 2011 PAS – Confidential and Proprietary

Your Alarms are Under Control

Alarm Management

• Alarm system is reliable

• Operators have time to detect all alarms


Your Alarms are Under Control

Alarm Prio. = Critical

Description = Waldo is on the loose

Critical Alarm -- SEVEREconsequences requiring IMMEDIATE action

Find Waldo…

The system will shut down in seconds

76543210

Lets Go to Grey Scale…

There he is…

Appropriate use of Color• Color is an

attention getter.

• Use for the abnormal, not the normal.

Lets Go to Grey Scale• Color blind view• 6% of males

have certain amount of color blindness

• Which valves are open/closed in this display?

I See Waldo• Reserve bright

colors for abnormal situations.

• Which other value is about to go into alarm?

2

Waldo was there the whole time…

The High Performance HMI Benefits

Study by Nova Chemicals and ASM® Consortium

Task With “Traditional”HMI

With High Performance HMI

Improvement

Detecting Abnormal Situations Before Alarms Occur

10% of the time 48% of the time A 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

Nova estimated $800,000 per year savings on 1 ethylene plant

Poor HMIs are cited as contributing factors to major accidents!

Data is Not Information: Is Garfield 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

PLT 310 x109 /L

Answer: Unless you are a veterinarian, how can you

know?


How About Now?

Contextualize information

Blood Tests for Fluffy -3

Test Results Range IndicatorLow – 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


How About Now?Blood Tests for Fluffy -3

Test Results Range IndicatorLow – 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

Tag = HCT Alarm = PVHIThe hematocrit (HCT) is the proportion, by volume, of the blood that consists of red blood cells

CausesTemporary dehydrationLung DiseaseBone marrow disorder

Corrective ActionsDrink waterLung examBone marrow exam

Aggregate information into the HMI


Where did I see this before??


Yes Dr. Mc Coy


Original Graphic

Typical “Process Pictorial” – a low performance overused paradigm


HP HMI?

Is this compressor running OK?

West East

Drive: 232.2 amps

Cooler

W. Vibration: 2.77 E. Vibration: 3.07

2.77MSCFH

155.2 °F 108.2 °F 166.1 °F55.7 psig

135.1psig

190.5 psig

Oil 155.2 °FOil 85.1 psi

65.1 °F


Analog in Industrial Examples

FLOW

RECYCLE COMPRESSOR K43

S.PRES

I.PRES

D.PRES

S.TEMP

I.TEMP

I.TEMP

Alarm Indicator

Desirable Operating Range

Alarm Range

Alarm Range

Show Values Show Trends

Buttons for additional functionality

D.TEMP

E.VIB

W.VIB

AMPS

OIL

PSI

OIL

TEMP

OutIn

2

Compressor Status Showing Alarm/Shutdown Limits


Analog in Industrial Examples

A Column Temperature Profile

Deviation or absolute numbers optionally toggled

20.124.2

25.6

27.8

28.9

+1.1

-0.7

+0.8

A goodprofile?

Yes, this one is.

Too hot at the top, too cold at the bottom

Optional:Line color indicates abnormality, alarm is not yet activated


Alarm Indications on Graphics

Diagnostic Priority

Priority 3 Priority 2 Priority 1

480.1 psi 480.1 psi 480.1 psi480.1 psi

2 1

Diagnostic Priority


480.1 psi 480.1 psi 480.1 psi480.1 psi4 3

Poor

Poor

Best!Suppressed

Alarm

480.1 psiS

480.1 psi No Alarm Indication 480.1 psiThe Worst!

Only a Color Change!

Multiple Coding: Color, Shape, Text

480.1 psi 480.1 psi480.1 psi 480.1 psi

Diagnostic Priority


Status Depiction• Bright color

is used to indicate abnormal situations only

(Shape is Unfilled and darker)

Pumps with Run Indication Sensor:

Wrong Better

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

Not Running

Running

Wrong Better

STOPPED

RUNNING(Shape is Filled and lighter)


Level Depiction

Poor Vessel Level

Indication

Better Vessel Level

Indication

Very Poor Vessel Level

Indication

Crude Feed TK-21

Trend Vessel Level

Indication

2 Hrs

CombinationVessel Level

Indication

2 Hrs 46.5%

2

0

100

Proper Hierarchy for Displays

HIERARCHY for Displays:• Level 1 – process Overview Display

– Entire operator’s Span of Control. “Single-Glance”

• Level 2 – process Segment Display– Sub-system

• Level 3 – Equipment Displays– Detailed equipment display

• Level 4 –Support and Diagnostic Displays– Interlocks, diagnostic screens, etc.

Level 1 OverviewReactor 1

ThioniteMid-RunONCLEAR

Prod:State:Agit:Locks:

Run Plan:Actual:

IN OUTBalance

Menus

MainMenu

FeedSys

AuxSys

Reactor1

L2

Trend Control

Comp A Comp B

72.0

80.0

2 HR

Cool CPC CRM

Rate

Reactor 2

CRM-114Mid-RunONCLEAR


Run Plan:Actual:

Balance

Comp A Comp B

60.0

68.0

2 HR

Cool CPC CRM

Rate

IN OUT

Hydrog A

BedA1

BedA2

Suct Dsch

OKOKOKCLEAR

VIB:BRG:OIL:Locks:

CycleComp A

470

500

FLOW

2 HR

Hydrog B

BedB1

BedB2

Suct Dsch

OKOKOKCLEAR

VIB:BRG:OIL:Locks:

CycleComp B

470

500

FLOW

2 HR

Alarms:ACKUNACK

ToggleList /Summary

P100

P210

P321

P441

Reactor2

HydrogA

HydrogB

L3 L4

70

80

%

12 HR

Key Performance Indicators

Conversion Efficiency

0.5

1.0

12 HR

Emissions Limit Ratio

Feed A Feed B Feed C SynG

Feed System Aux Systems

Atv 1 Atv 2 Pres %IP

Clr T-In T-Out Visc

CWT CWP S10

PWR VentP VentT

C57D Null-A Jup2

S200

MGA

Grok2

2

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

LVL

LVL

Level 2PSOAUTO

76.8 MPH76.088.5 %

Main Feed

Main Feed MPH

72.0

80.0

-60 -30-90 2 Hours

PSOAUTO

11.9 MPH12.022.3 %

Additive 1

Additive 1 MPH

10.0

14.0

-60 -30-90 2Hours

PSOAUTO

4.0 MPH4.0

44.3 %

Additive 2

Additive 2 MPH

2.0

6.0

-60 -30-90 2 Hours

VENT SYS

Analysis: Purity %

32.0

40.0

-60 -30-90 2 Hours

Analysis: Inhibitor Concentration %

4.0

6.0

-60 -30-90 2 Hours

AgitatorON

Reactor M5

Pump 1RUNNING

PSOAUTO

95.044.3 %

M5 Pressure98.0 psig

PSOAUTO

70.054.3 %

M5 Level %71.0 %

ThioniteProduct: Mid-Run

52.3 %

5.0 %

CoolantFlow

CoolantTemp

PSOAUTO

45.054.3 %

M5 Temp45.0 °C

To Coils

COOLING SYS

92.0 MPHPRODUCT

Temperature °C

40.0

48.0

-60 -30-90 2 Hours

Diagnostics1-OK

PumpsNeeded 1

SHUTDOWN

M5

Run Plan:Actual:

FREEZEM5

IN

Reset

OUT

Calc Diff:

-10%

+10%

Hours: 238.1Since:

State:

19707 19301

Material Balance

2.1 %

06/02/07 14:00:00

ISOLATEM5

Pump 2STOPPED2-BAD

M4MainMenu

- Level 3 -M5

Interlocks

FeedSystem

Product Recovery

Level 1 ReactionOverview

M5 Sequence Overlay

PurgeRate

ConversionEfficiency

Cat.Activity

Reserve Capacity

M5 StartupOverlay

M6- Level 3 -

M5 Cooling System

Feed Components: A - B - C

+/- 5 psi, 2hr

+/- 1 %, 2hr

Trend Control

4

Level 3

PSOAUTO

76.8 MSCFH76.088.5 %

Flow Demand

RUNNING

PSOCAS

90.090.0 %

WC Speed

65.0 °C

West Comp Discharge Temp °C

40.0

50.0

-60 -30-90 2 Hours

East Comp

MainMenu

OHSystem

Product Recovery

CompressionLevel 2

West Sequence Overlay

West StartupOverlay

Comp Cooling System

Trend Control

1st

Stage

2nd

Stage

CW

32.0 °C

20.0 °C

28.0 °C

WESTCOMP

OH

44.0 °C

90.8 %

48.0 psi

90.0 psi

1 Stgpsi

EAST COMP

Speed

90.8

20.1 psiEAST COMP

2 Stgpsi

48.090.0

SHOW / HIDE VALUES

CLRIn

SPEED CASCADEIN EFFECT

CLROut

NORMALIZESCALE

65.0 32.0

WindingTemp

111.0 °C

111.0

West Compressor Interlock W-1

Overspeed

Or Winding Temp High

Or Vibration High

Or 1 Stg High Pres

Or 2 Stg High Press

Or Suction Pres Low

Or Oil Pres Low

Initiator ActionValue Status

OK

OK

OK

OK

OK

OK

OK

Shut Down West Comp AND

Close Inlet & Outlet Block ValvesAND

Override East Comp Speed to 100%

West Comp Flow MSCFH

45.0

55.0

-60 -30-90 2 Hours

48.4 MSCFH

West Comp Speed %

85.0

95.0

-60 -30-90 2 Hours

SHUTDOWNWESTCOMP

- Level 4 -Procedures

RECOVERY

IDLEWESTCOMP

PURGEWESTCOMP

West Compressor

7 Steps for Creating High Performance Displays By PAS

1. Adopt a High Performance HMI Philosophy and Style Guide2. Assess and benchmark existing graphics against the HMI Philosophy 3. Determine specific performance and goal objectives for the control of

the process, for all modes of operation4. Perform task analysis to determine the control manipulations needed

to achieve the performance and goal objectives5. 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

6. Install, commission, and provide training on the new HMI7. Control, maintain, and periodically reassess the HMI performance

ReviewHP HMI Components:

1. Alarm Management2. Grey Scale – Limited use of color3. Situation awareness objects and depictions4. Objective based design & Hierarchy5. Embedded information in context

Reactor 1



Run Plan:Actual:

IN OUTBalance

Menus

MainMenu

FeedSys

AuxSys

Reactor1

L2

Trend Control

Comp A Comp B

72.0

80.0

2 HR

Cool CPC CRM

Rate

Reactor 2



Run Plan:Actual:

Balance

Comp A Comp B

60.0

68.0

2 HR

Cool CPC CRM

Rate

IN OUT

Hydrog A

BedA1

BedA2

Suct Dsch

OKOKOKCLEAR

VIB:BRG:OIL:Locks:

CycleComp A

470

500

FLOW

2 HR

Hydrog B

BedB1

BedB2

Suct Dsch

OKOKOKCLEAR

VIB:BRG:OIL:Locks:

CycleComp B

470

500

FLOW

2 HR

Alarms:ACKUNACK

ToggleList /Summary

P100

P210

P321

P441

Reactor2

HydrogA

HydrogB

L3 L4

70

80

%

12 HR



0.5

1.0

12 HR





Clr T-In T-Out Visc

CWT CWP S10

PWR VentP VentT

C57D Null-A Jup2

S200

MGA

Grok2

2


LVL

LVL

Reactor 1



Run Plan:Actual:

IN OUTBalance

Menus

MainMenu

FeedSys

AuxSys

Reactor1

L2

Trend Control

Comp A Comp B

72.0

80.0

2 HR

Cool CPC CRM

Rate

Reactor 2



Run Plan:Actual:

Balance

Comp A Comp B

60.0

68.0

2 HR

Cool CPC CRM

Rate

IN OUT

Hydrog A

BedA1

BedA2

Suct Dsch

OKOKOKCLEAR

VIB:BRG:OIL:Locks:

CycleComp A

470

500

FLOW

2 HR

Hydrog B

BedB1

BedB2

Suct Dsch

OKOKOKCLEAR

VIB:BRG:OIL:Locks:

CycleComp B

470

500

FLOW

2 HR

Alarms:ACKUNACK

ToggleList /Summary

P100

P210

P321

P441

Reactor2

HydrogA

HydrogB

L3 L4

70

80

%

12 HR



0.5

1.0

12 HR





Clr T-In T-Out Visc

CWT CWP S10

PWR VentP VentT

C57D Null-A Jup2

S200

MGA

Grok2

2


LVL

LVL


Conclusion•High Performance HMI enables operators to be proactive

• Safety and Profitability

•Best practices have been published on how to design effective HMIs

•A High Performance HMI is now practical and achievable

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Questions

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High Performance HMI · PPA Symposium Time for new paradigms High Performance HMI Alain Wullaert December 8th, 2011