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
• Transition handling
• Minor disturbances rejection
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
• Transition handling
• Minor disturbances rejection
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
© 2011 PAS – Confidential and Proprietary
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?
© 2011 PAS – Confidential and Proprietary
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
© 2011 PAS – Confidential and Proprietary
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
© 2011 PAS – Confidential and Proprietary
Where did I see this before??
© 2011 PAS – Confidential and Proprietary
Yes Dr. Mc Coy
© 2011 PAS – Confidential and Proprietary
Original Graphic
Typical “Process Pictorial” – a low performance overused paradigm
© 2011 PAS – Confidential and Proprietary
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
© 2011 PAS – Confidential and Proprietary
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
© 2011 PAS – Confidential and Proprietary
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
© 2011 PAS – Confidential and Proprietary
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
Priority 3 Priority 2 Priority 1
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
Priority 3 Priority 2 Priority 1
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)
© 2011 PAS – Confidential and Proprietary
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
Prod:State:Agit:Locks:
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
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
Prod:State:Agit:Locks:
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
Reactor 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
Prod:State:Agit:Locks:
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
© 2011 PAS – Confidential and Proprietary
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
1
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BFP 41
BFP 41
BFP 41
© 2011 PAS – Confidential and Proprietary
Questions