Proper Graphics for Operator Insert Photo Here ...

1 Copyright 2011 Rockwell Automation, Inc. All rights Photo HereRockwell Automation Process solutions User Group (PSUG)November 14-15, 2011 Chicago, IL McCormick Place WestThe High Performance HMIP roper Graphicsfor Operator EffectivenessMark CarriganPASA genda PAS Overview The History of HMIs in Industry High Performance HMI Justification Common But Ineffective Process Depictions High Performance Graphic Principles and Elements High Performance Graphic Hierarchy The 7-Step High Performance HMI Development Process SummaryMark Carrigan Vice President, Global Business Development at PAS Roles have included Operations Management Managing Director.

2 PAS Middle East The History of HMIs in Industry High Performance HMI Justification Common But Ineffective Process Depictions High Performance Graphic Principles and Elements High Performance Graphic Hierarchy The 7-Step High Performance HMI Development Process SummaryAbout PASF ounded in 1993 Privately held Texas Corporation Process Automation solutions Provider 110 People in 9 Offices worldwide Sustainable growth - 300% in 7 yearsBusiness Strategy Focused on long term growth Significant investment in R&D; >20% of annual revenue Ten-year plan on software & technologyIndustry Organizations & Strategic Partners EPRI, ISA, AICHE, NPRA, EMMUA 191 Regional engineering firms PAS solutions Improve Disturbance Rejection Minimize Operator Loading Optimize Situational Awareness Enable Accurate Operator Actions Expand Layers of Protection for SafetyOperations EffectivenessAchieve Superior Operator Performanceand Reduce Vulnerabilitiesduring abnormal situations and steady state EffectivenessMap the Automation Genome and expose new possibilities for knowledge retention, collaboration.

3 And decision support. Retain Important Plant Knowledge Provide a Collaboration Platform Enable Change Tracking/Defect Detection Provide Disaster Recovery Ensure Accurate Documentation Realize the Full Potential of Your People and Automation SystemsCopyright 2011 Rockwell Automation, Inc. All rights Photo HereRockwell Automation Process solutions User Group (PSUG)November 14-15, 2011 Chicago, IL McCormick Place WestThe High Performance HMI: Proper Graphicsfor Operator EffectivenessThe HMI of the Past Provided the Big Picture Limited Capability Many Process Trends Status at-a-glance Equipment StatusProcess ValuesHuman PerceptionAlarmsThe DCS Arrives The Keyhole View Expensive Screens Contributed to over-alarming Lost the Big Picture Early Group Display showing 8 sensorsDCS Graphics Introduced But No Guidelines!

4 Poor Graphics Encourage Poor Operating PracticesCommon HMI DepictionsCommon, but ineffectiveprocess depictions! Numbers sprinkled on a screen Inconsistent, improper use of colorNo trendsNo condition informationAnd Even Worse Vendor Improved Graphic Capability yields even worse 10% of the screen is used to show poorly-presented numeric data, 90% is a just a pretty picture Other Industries Do It Better Speed Altitude Position Course Time Enroute Time to next Waypoint Time to Destination Fuel Remaining Proximity to Ground Proximity to Rising Terrain Nearby Airports Positions of nearby aircraft Real-time weather & lightning Glide Radius Engine diagnostics Data on Available Services at Airports Comm & Nav Frequencies Instrument Approaches Lots more!

5 GARMIN 1000 Avionics SystemThe High Performance HMIS tudy by Nova Chemicals and ASM ConsortiumTaskWith Traditional HMIWith High Performance HMII mprovementDetecting Abnormal Situations Before Alarms Occur10% of the time48% of the timeA 5X increaseSuccess Rate in Handling Abnormal Situation70%96%37% over base caseTime to Complete Abnormal Situation min41% reduction$800,000 per year savings anticipated on 1 ethylene plantTime after time, poor HMIs are cited as contributing factors to major accidents!Texas City BP HMI a Contributing Factor No Overview No trends No condition indication Essentially just a P&ID segment sprinkled with live values.

6 No material balance (FLOW IN and FLOW OUT are on different Graphics ) Inconsistent colors and alarmsImage taken from the CSB reportData is Not Information: Is Fluffy Sick?Blood Tests for Fluffy 6 x109 x109/ x109/LPLT310 x109/LAnswer: Unless you are vet, how can you know?What About Now?After awhile, you might figure it Tests for Fluffy 6 - x109 x109 x109 x109/L175 - 500 How About Now?ABNORMAL VALUES can be seen at a Tests for Fluffy -3 TestResultsRangeIndicatorLow Normal - 6 - x109 x109 x109 x109/L175 - 500 Data is Not Information: Common XYZ ABC DP INH2012-15 XYZ ABC DP INH2012-15 MPPHMost Graphics in the world basically look like this!

7 Lots of Data Not Much Information Poor Presentation High Mental Workloadto Decipher Cannot grasp what is going on at-a-glance Analog in Industrial ExamplesA Column Temperature ProfileDeviation or absolute numbers optionally + + goodprofile?Yes, this one hot at the top, too cold at the bottomOptional:Line color indicates abnormality, alarm is not yet activatedP&IDs are not HMIs: A Poor ParadigmTypical P&ID Process Pictorial a low performance, overused paradigmWestEastDrive: Vibration: Vibration: psigOil FOil FInformation is Data in Context Made UsefulFLOWRECYCLE COMPRESSOR Indicator Appears here with Priority Level and ColorDesirable Operating Range shown as dotted linesAlarm Range depicted and (for some) shutdown valueAlarm Range depicted and (for some)

8 Shutdown or interlock initiatorShow ValuesShow TrendsButtons for additional Status Showing Alarm/Shutdown LimitsAnalog is PowerfulAnalog Indicators with values, direction, and historyOptional Enhancements for Moving Analog variability in the last direction rolling 10 in Industrial ExamplesMaterial Balance IndicatorsScrubber Material WarningDiff: : : 06/02/07 14:00:00 Material WarningDiff: : : 06/02/07 14:00:00 in Industrial ExamplesMaterial Balance Indicator AnimationScrubber Material WarningDiff: : : 06/02/07 14:00:00 Importance Of TrendsCurrent PressureAlarm LimitShutdown psig250 psig300 psigShutdown-2 HRS25030020015010050 AlarmShutdown-2 HRS25030020015010050 AlarmShutdown-2 HRS25030020015010050 AlarmShutdown-2 HRS25030020015010050 AlarmShutdown-2 HRS25030020015010050 AlarmShutdown-2 HRS25030020015010050 AlarmValueNeedingTrendVery Different Situations that only trends can show!

9 The Importance Of mph % Steam#7 RHP COLUMNFeed Temp Deg Flow Temp Deg % Steam HOURST oggle OUTPUT Proper Auto-ranges Show boundaries of What is good Custom Elements for StartupsAlways try to clearly depict: Where am I? How am I doing vs. what is good? Reactor 7 Startup0 TemperatureDeg C+30+60+ PrinciplesPoor Vessel and Line Depiction !Crude Feed TK-21 CRUDE FEED TK-21 Better Vessel and Line DepictionPROD TANKSCRUBBERTo ScrubberTo Product TankNot a navigation targetNavigation target Don t get fancy Avoid 3-D objectsProper Level Depiction Poor Vessel Level IndicationBetter Vessel Level IndicationVery Poor Vessel Level IndicationCrude Feed TK-21 Trend Vessel Level Indication2 HrsSimple.

10 Non-Distracting Element DepictionCRUDE FEED Output %numbers can be more effective than tiny scalesTinyIllegible ScalesTinyIllegible ScalesStatus DepictionBright saturated color is used to indicate abnormal situations only(Shape is Unfilled and darker)Pumps with Run Indication Sensor:WrongBetterPumps without Run Indication Sensing have a fill matching the background:Not RunningRunningWrongBetterSTOPPEDRUNNING( Shape is Filled and lighter)Basic Principles - HierarchyHIERARCHY for Displays: Level 1 Process Area Overview Entire Operator Span of Control. Single-Glance Level 2 Process Unit Control Sub-unit controlled by Operator Level 3 Process Unit Detail Equipment or controller Level 4 Process Unit Support and Diagnostic Displays Interlocks, ESDs, diagnostic screens, etc.