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Standards
Certification
Education & Training
Publishing
Conferences & Exhibits
Situational Awareness
The Next Leap in Industrial HumanMachine Interface Design
2015 ISA Water / Wastewater and Automatic Controls SymposiumAugust 4-6, 2015 – Orlando, Florida, USA
Speakers:John Krajewski
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA 2
Presenter – John Krajewski
• John has 20+ years of experience in industrialautomation and control systems.
• John began his career working as a Control SystemEngineer in the potable water industry.
• Subsequently, John worked as an Application Engineerfor a System Integrator who primarily focuses on thepharmaceutical and biotech industries.
• He joined Wonderware Inc. in April 2000 as a SeniorApplication Developer in the Product MarketingDepartment.
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
IncreasedSize and
Complexity
IncreasedData
Volumes
RemoteOperations
IncreasedLevels of
Automation
Staffing/Education
Challenges
Trends in Industrial Automation
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
1970’s 1980’s 2000’sFUTU
RE
HMI Evolution/Current State
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
Althoughpleasant to see,
much of thisgraphic is
irrelevant to thecontrol.
Key Principles –Distracting and Irrelevant Detail
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
• Although pleasant tosee, much of this
graphic is irrelevant tocontrol the process.
• These are the onlyobjects providinginformation to the
operator:
Key Principles –Distracting and Irrelevant Detail
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
The average percentages shown had the following:•People and work Context Factors: 35% - 58%•Equipment Factors: 30% - 45%•Process Factors: 3% - 35%
Abnormal SituationA disturbance or seriesof disturbances in aprocess that causeplant operations todeviate from theirnormal operating state.
Source: ASM Consortium
Impact of Human Error
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
Situational Awareness
The perception ofenvironmentalelements with respectto time and/or space,the comprehension oftheir meaning, and theprojection of theirstatus.
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
• Poorly performing alarm systems ANDHMIs are contributing factors to majoraccidents and poor operatingperformance.
• Proper Alarm System Management andAlarm System Performance is essentialto maximum-efficiency operations.
• There are multiple contributing factors:
AlarmManagement
Human MachineInterface
ControlLoop
Performance
Safe and Reliable Control
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
Measurable Costs/Value
Raw Materials Process Products/Services
En
erg
yW
as
te
$
$
$
$
Business Value = Products(Availability) – Energy – Raw – Waste
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
Goal Oriented Design
• Common Mistake – The System is the Goal.
GoalDirectedTaskAnalysis
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
Display structure
Level 1 – Area-wide overviews– KPIs, summary status information
Level 2 – Facility-wide overviews– key operating screens, specialty pages
Level 3 – Detailed operating information– similar to most current screens
Level 4 – Auxiliary information– help screens, trend pages, etc.
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
Reduced Navigation
Start-up/Shut Down Info
NO MASTER FUEL TRIPPURGE COMPLETEFUEL GAS ONABC RESETABC MODE MANUALIGNITOR HEADER PERMISSIVES SATISFIEDGAS HEADER PERMISSIVES SATISFIED
STM F BFW F
DL
BP
FD (P)
% O2
STMT
Air F
IGN
B2IGMN
BURNER STARTREGISTER OPENMODE AUTOIGNITOR ONIMPELLER OUTOIL BURNER ONSAB ON
N W COO2
BTU/C
900#
TN-BN
TS-BS
TS-BN TN-BS
BFW
Boiler Metal Temperatures
FG
202 Boiler Start-up
% MCR
100
0
BM %
100
0
LB %
50
0
202
-50
Pre
ssu
re(P
SIG
)Time (min)
10 20 30 SAT Steam0
100
200
300
400
500
600
700
800
900
1000
Sat Steam ROC(oC/hr)
Last hr: 0.00Current: 0.00
SH Steam ROC(oC/hr)
Target: 0.00Current: 2.00
To 100oC DrumBottom Temp (oC)
Target: 0.00Current: 2.00Last hr: 0.01
Drum Press ROC(psig/min)
Last hr: 0.20Current: 0.00
Task Orientated Level Two Displays
-To startup operator had to visit 12 screens.
-Operational level 1 screen to start up a Boiler
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
Color and Attention
Source: NASA Ames Research Center Color Usage Lab
http://colorusage.arc.nasa.gov/popout.php
Color is a powerful way to guideattention
– Your eye is automatically drawn tocolored objects
• This is called the “pop out” effect
– Now try this one…
Color is a powerful way to guideattention
– Your eye is automatically drawn tocolored objects
• This is called the “pop out” effect
– Find the the “L”s and “I”s
in this picture…
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
• Situational Awarenessfocused displays takeadvantage of the “popout” effect to guideoperators’ attention tovalues that are inalarm
Click andwatch forthe alarm…
Color and Attention
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
Color and Attention
Source: NASA Ames Research Center Color Usage Lab
http://colorusage.arc.nasa.gov/popout.php
The Effectiveness of the Pop Out Effectdrops dramatically as additional colorsare added.
– Lets add just 3 more colors and seethe impact…
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
Different tastes…
Reactor 1
ThioniteMid-RunONCLEAR
Prod:State:Agit:Locks:
Run Plan:Actual:
IN OUTBalance
Menus
MainMenu
FeedSys
AuxSys
Reactor1
L2
TrendControl
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
TrendControl
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
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
Severity 1 response time < 5min
2
4
3
Severity 2 response time < 30min
Severity 3 response time < 60min
Severity 4 response time < 120min
1
Best Practices: Alarm signalingin the HMI displays
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
Navigation Badges
Reactor 31
1 2 1 3
Reactor 323
Reactor 33
2
Overview
1 4 1 6
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
Equipment Meters/Polar Stars Dashboard Tools
• Agitator/Settler
• EquipmentStatus
• Feeder
• Hand SwitchSelector
• HeatExchanger/Fan
• Loop Block
• MiscellaneousEquipment
• Multistage Pump
• Numeric Data
Block
• Output Bar
• Parallel ControlValve
• Pump/Blower/Rotary Valve
• RotatingEquipment
• Sequence Button
• Tank/Vessel
• Thickener
• Valve/Damper
• Invisible ProfileMeter
• KPI Bar
• Meters
• Multi-LevelMeter
• Rake HeightMeter
• RPM Meter
• MeterConnector
• Small FlowTracker
• Polar Star 3Spoke
• Polar Start 4Spoke Diamond
• Polar Start 4Spoke Square
• Polar Star 6Spoke
• Polar Star 8Spoke
• Bar Chart
• Box Chart
• Bullet Graph
• Column Chart
• Column ChartPairs
• Column ChartTrips
• Deviation Chart
• ParallelCoordinatesChart
• Pie Chart
• StackedColumn Chart
• StackedColumn ChartAlarms
• Target Graph
• ValueComparisonChart
• VariableMonitoring Bars
• Win Loss Chart
Wonderware Situational AwarenessSymbol Library
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
Information comes from putting data in context– When data is presented without context it forces operators
to remember or search for the related values
Data withoutcontext
How far is it fromsetpoint?
Is it getting close toalarming?
Is it inside thenormal operatingrange?
At best, this isinconvenient – butduring an upset it canlead to slower responsetimes and cause costlyerrors
Data vs Information
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
m3/h
FIC 123
C
Meter Components
PV in ideal range
PV near edge ofideal range –watch moreclosely
PV outside ofideal range –considertaking action
Glance Test
When you click, an example will appearbriefly at the far right of the screen –see if you can tell whether the PV isinside the optimal range or not
Each examplewas only shownfor ½ of a second
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
Benefits…
Task With TraditionalHMI
With HighPerformance HMI
Result
Detecting AbnormalSituations beforealarms occur
10% of the time 48% of the time A 5X increase
Success rate inhandling abnormalSituation
70% 96% 37% over basecase
Time to completeabnormal situationtasks
18.1 min 10.6 min 41% reduction
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
How do you eat an elephant?
One bite at a time…
2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA
Past Future
Process Parameters Situational Awareness
Labor Resources Information Craftsmen
Reactive Operations Proactive Operations
Operating a ProcessReal Time Business
Management
Evolving Industrial Operations
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