maximize operator effectiveness papers... · the ansi/isa-101.01-2015: human machine interfaces for...

30
Maximize Operator Effectiveness: High Performance HMI Case Studies, Recommendations, and Standards Part 2 of 2 A PAS White Paper Version 3.0 Bill Hollifield Principal Alarm Management and HMI Consultant, PAS Hector Perez High Performance HMI Product Manager, PAS High Performance HMI 3.0 - Part 2 | Cover © PAS Global, LLC 2017

Upload: others

Post on 25-Oct-2019

21 views

Category:

Documents


3 download

TRANSCRIPT

Page 1: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

Maximize Operator Effectiveness:

High Performance HMI Case Studies, Recommendations, and Standards

Part 2 of 2

A PAS White PaperVersion 3.0

Bill HollifieldPrincipal Alarm Management and HMI Consultant, PAS

Hector PerezHigh Performance HMI Product Manager, PAS

High Performance HMI 3.0 - Part 2 | Cover© PAS Global, LLC 2017

Page 2: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

Table of Contents

High Performance HMI 3.0 - Part 2 | Table of Contents© PAS Global, LLC 2017

Introduction and Overview ......................................................................................................................................................... 1

A Real World Case Study and Test of HPHMI Concepts ................................................................................................. 3

The Level 1 Overview .................................................................................................................................................................. 4

The Level “1.5” Pulverizer Overview Graphic ..................................................................................................................... 5

The Level 2 Pulverizer Control Graphics ............................................................................................................................. 6

Abnormal Situation Response Graphics ............................................................................................................................. 7

The Testing ..................................................................................................................................................................................... 8

The Results ..................................................................................................................................................................................... 9

PowerGraphiX® .............................................................................................................................................................................. 9

Paradigm Busting: The Pipeline Overview ............................................................................................................................ 13

A Review of HMI Standards ........................................................................................................................................................ 16

API-1165: Recommended Practice for Pipeline SCADA Displays ............................................................................... 17

ISA-101: Human-Machine Interfaces for Process Automation Systems .................................................................... 17

The PAS Seven Steps HPHMI Work Process ........................................................................................................................ 21

HPHMI Implementation on a Budget ...................................................................................................................................... 22

Conclusion ......................................................................................................................................................................................... 23

Typical Table of Contents of an HPHMI Philosophy and Style Guide ......................................................................... 24

About the Authors ......................................................................................................................................................................... 27

References ......................................................................................................................................................................................... 28

Page 3: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 1© PAS Global, LLC 2017

Introduction and OverviewThe process control and automation industry has spent billions on improving process safety

via complex, instrumented systems. Yet, we continue to frequently see industrial incidents,

accidents, and fatalities in the news. The causes are generally not the failure of such automated

systems but are instead the result of a wide variety of human errors. PAS firmly believes that

addressing the causes of human error and the improvement of Operator Effectiveness is of the

highest importance. The proper use of such technologies as High Performance HMITM (HPHMI)

and Alarm Management can actually save lives and prevent injuries. Detailed information on

these should not be withheld, and that is why we offer this and other white papers freely.

They can also significantly lessen process upsets, improve process efficiency, and increase

productivity.

The human-machine interface (HMI) is the collection of screens, graphic displays, and other

technologies used by the operator to monitor and interact with the control system (typically

DCS or SCADA). Several major accidents, such as the Texas City refinery explosion in 2005,

have cited poor HMIs as a significant contributing factor. The design of the HMI plays a critical

role in determining the operator’s ability to effectively manage the operation, particularly in

quickly detecting and resolving an abnormal situation, which is the most important task of an

operator. A poor HMI can actively interfere with this ability.

For several reasons, the current designs and capabilities of most HMIs are far from optimal

for running the kinds of complex operations we have in industry. Most HMIs consist simply of

schematic or P&ID style graphics covered in numbers. Such displays provide the operator large

amounts of raw data but almost no real information. They are difficult to interpret and provide

inadequate situation awareness to the operator.

Since we published The High Performance HMI Handbook in 2008, improving HMI has become

one of the hottest topics in the automation industry. In that book, we explained exactly why

most current HMI practices were poor, and we put forth the proper principles and details for

making graphics significantly better. Many companies have adopted those principles and have

completed migrations to improved graphics. Many more have such efforts currently underway.

This two-part paper provides a history, justification, and detailed plan of action for the

improvement of a process control HMI. Here is an overview of the contents.

Page 4: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 2© PAS Global, LLC 2017

Part 1 (Separate Document)Examples: We provide typical examples of common but poor HMIs, along with highly

detailed depictions of improved methods that provide for much better operator situation

awareness and control.

Principles: We cover the most important aspect of High Performance HMI, the display

of information to the operator rather than raw data. Many other necessary graphic

principles including the correct way to use color are provided. Depictions of detailed

graphic elements are included.

Hierarchy: HPHMI graphic designs must reflect a proper hierarchy – the exposure of

additional detail as needed. We include examples of graphics that illustrate this hierarchy,

along with the work processes used to design such graphics.

Part 2Case Studies: Since the publication of our 2008 book, many projects have provided

for the development of real world case studies. We include two such studies in this

paper. The first was conducted by the Electric Power Research Institute (EPRI) but is

applicable to all types of process operations. The second shows how a major company

has improved performance and significantly lowered costs via company-wide adoption

of standardized High Performance graphics. This has led to a major HPHMI product

innovation for the power industry: PowerGraphiX®.

We also provide an example as to how “out-of-the-box thinking” can address HMI issues,

in the discussion of a Pipeline System Overview Display.

Standards Review: Two standards documents available on HMI are discussed, including

the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems

released in August 2015.

HPHMI Work Processes and Implementation Guidance: The work process for HMI

improvement is described. We also address the most common issues encountered in

HMI improvement and cost effective ways to transition to High Performance graphics.

If your facility utilizes a process control system with a computer-based HMI, you will find this

information useful. This white paper augments the detailed content in The High Performance

HMI Handbook.

Page 5: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 3© PAS Global, LLC 2017

A Real World Case Study and Test of HPHMI ConceptsThe following section is taken from a study conducted by the Electric Power Research Institute

(EPRI).

Operator HMI Case Study: The Evaluation of Existing “Traditional” Operator Graphics vs. High

Performance Graphics in a Coal Fired Power Plant Simulator, Product ID 1017637

The EPRI study tested the HPHMI concepts in this paper at a large, coal-fired power plant. The

plant had a full and accurate simulator used for operator training. The existing graphics on the

simulator (created in the early 1990s) operated the same as those on the actual control system.

PAS was retained to prepare several High Performance graphics for the simulator. Several

operators were then put through multiple abnormal situations using both the existing and the

new High Performance graphics.

Four examples of the existing graphics are in Figure 1. They have the following characteristics:

● Many controller elements are not shown on any of the existing graphics.

● No graphic hierarchy.

● No Overview.

Figure 1: 1990s Graphics from the EPRI HPHMI Test

• Existing Overview

Page 6: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 4© PAS Global, LLC 2017

● Numbers and digital states are presented inconsistently.

● Poor graphic space utilization.

● Inconsistent selectability of numbers and elements.

● Poor color choices, overuse, and inconsistencies.

● Bright red and yellow used for normal conditions.

● Poor interlock depiction.

● No implemented trends (“trend-on-demand” rarely used by the operators).

● Alarm conditions generally not indicated on graphics – even if the value is a

precursor to an automated action.

The operators used dozens of such graphics to control the process. PAS prepared the following

High Performance graphics:

● Power Plant Overview (Level 1) – Figure 2

● Pulverizer Overview Graphic (Level “1.5”) – Figure 3

● 8 Individual Pulverizer Level 2 Control Graphic – Figure 4

● Runback 1 and 2: Special Abnormal Situation Graphics – Figure 5

The Level 1 Overview

Figure 2: Example Level 1 Display

AD-ONPULVStatus

A2 CWP

B2 CWPE-ONC-ONF-OFF

H-ONA-OFFG-ON

Alarms

E

B

F

C

G

D

H

PUMPS ANDFANS

Pump Status

ON

ON

A2 HWP

B2 HWPON

OFF

C2 HWP

SUBFPON

ON

A2BFPT

B2BFPTON

ON

A2 ECW

B2 ECWON

ON

Fan StatusA2 FDON

ON

B2 FD

B2 IDON

ON

A2 PA

B2 PAON

ONA2 ID

7.1

A/F Ratio

9.4

BBDpH

9.4

EconpH

Boiler

775

Econ GasOut °F

300 -0.5

Aux Stmpsig

25 25 7.0Auto

351

25 6.0 21 0.45 0.9 200 90

F. in.H2OA2IDStall

A2FDStall

Fans B2IDStall

B2FDStall

Econ% O2

Sec Airin. H2O % Opac

NOX#/MMBTU

SO2#/MMBTU

CEMS COppm

Inst Airpsig

702.1 640.1 -5.2

MVARTurbine-GeneratorGross MW

60.00 0.2 0.2

LPT-Ain.hg

49.1 3.13.1 20.1 -0.5 9.0

H2psig

H2°F

Turb Oil°F

StatorGPM

Condenser-Feed WtrA2 BPFT B2BPFT

Drum LvlIn. H2O

HW Lvlin.H2O

DA Lvlin.H2O

DA WideFT H2O

Cond Hdrpsig

104 115Auto Auto

Net MW HZLPT-Bin.hg

400Auto

0.0Auto

25

B-ON

05-31-1413:22:07

Unit 2Overview

1

Total Alarms

0

5

80

-450

-15 1 HR

50005000

15

SteamKLBH

4100Fd WtrKLBH

4580

DrumLvl in.

-0.5

-30 -15

0

-450

-5 1 HR

75001250

5

AirKLBH

5820Coal

KLBH980

FurnPres-0.5

-30 -15

600

-45600

0 1 HR

120012003000

Steam°F

990Reheat

°F1005

Steampsig2400

-30 -153

2

2

2

Page 7: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 5© PAS Global, LLC 2017

The Overview graphic shown in Figure 2 (repeated from the Part 1 document) shows the key

performance indicators of the entire system under the operator’s control. The most important

parameters incorporate trends. It is easy to scan these at a glance and detect any non-normal

conditions. Status of major equipment is shown. Alarms are easily detected.

The operators found the overview display to be far more useful than the existing graphics in

providing overall situation awareness and also very useful in detecting burgeoning abnormal

situations.

The Level “1.5” Pulverizer Overview GraphicThe operator controls eight identical, heavily instrumented, and complex pieces of equipment

called coal pulverizers. At normal rates, seven are in use and one is on standby in case of a

problem. The seven that are running should be showing almost identical performance. It was

immediately apparent that an “Overview” graphic of just these eight items would be useful

to the operators, since much of their activity is in monitoring and manipulating them. Being

mechanical, they are subject to a variety of problems and abnormal conditions. There were

three separate existing graphics needed for monitoring and controlling each pulverizer, 24 in

total for them all. Monitoring using 24 graphics was difficult for the operators.

Figure 3: The Level “1.5” Pulverizer Overview

08-15-2012 14:22:09PULVERIZER OVERVIEWCoal Flow Trend

Coal Flow

KLB/HR

2 Hrs1

140

EFGH

7574

7845

7674

7574

5150

5050

7565

5551

A A A A M A A A

113102

112113

0113

112112

A B C D E F G H

Mill Amps Trend

A A A A M A A A

4243

4244

043

4343

A B C D E F G H

Diff Pres Trend

A A A A M A A A

8.09.8

9.19.0

0.68.0

8.58.3

A B C D E F G H

Pri. Air Flow Trend

A A A A M A A A

204233

204205

0205

204205

A B C D E F G HA A A A M A A AA B C D E F G H

7574

7877

7878

7574

00

5050

7576

5551

S. Air Flow Trend

A A A A M A A A

204205

204205

0205

204205

A B C D E F G HA A A A M A A AA B C D E F G H

Primary Damper

7574

7877

7878

7574

3030

5050

7573

5551

A A A A M A A AA B C D E F G H

North Damper South Damper

7574

7877

7878

7574

4040

5050

7565

5551

C/A Temp Trend

A A A A M A A A

135135

135135

277135

135135

A B C D E F G HA A A A M A A AA B C D E F G H

7574

7877

7878

7574

5050

5050

7573

5551

A A A A M A A AA B C D E F G H

Hot Damper Cold Damper

ON

Pulverizer Status

G

E

C

AB

D

H

F

ON

ONON

ON

ON

ONON

DiagBurnMaint

ABCD

Diff PresPSI

2 Hrs0

16

EFGH

ABCD

SWG Valves

M1Select

Main Flame

IgniterFlame

Fuel Type:

Flm Mnt Mod

90 90

30

M2

OFF

30OFF OFF

OPEN NORM

GAS-1

OPEN NORM

B

Main Menu L1 Overview Runback 1/2 PULV A PULV B PULV C PULV D PULV E PULV F PULV G PULV H

S

3

2 2

2

SS

S

Page 8: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 6© PAS Global, LLC 2017

The new Pulverizer Overview in Figure 3 depicts more than 160 measurements on a single graphic!

The key to making this understandable is that the devices are supposed to run alike. Instead of

blocks of indicators for each pulverizer being grouped together, the same measurement from

each pulverizer is grouped together. Any individual unit operating differently than the others

stands out. The unit that is in standby service also is easily seen. Air damper command vs. actual

positions, a consistent source of problems, is clearly shown.

Note that the trends seemingly violate our recommendation of showing no more than three

or four traces on a single trend. In this case, what the operator is looking for is any trend line

that is not “bunched in” with the others. For such a condition, having these eight traces was

acceptable. Note that the standby pulverizer’s trace is normally on the bottom.

Even with such a “dense” information depiction and with so many measurements, the operators

found it easy to monitor all eight devices and easily detect burgeoning abnormal situations. It is

easy to scan your eye across the screen and spot any elements that are inconsistent (Pulverizer

“B” in the depiction). Alarm conditions are also easy to spot.

Note that control actions are not taken on this screen but rather on the eight individual Level 2

graphics, one for each pulverizer. This graphic is “in-between” Level 1 and 2, as it is an overview

of a complex sub-part of the operator’s responsibility. The most common sources or problems

are depicted.

The Level 2 Pulverizer Control Graphic05-31-2012 11:13:55PULVERIZER A – Level 2

5.9AUTO

10.082%

GAS PSI

40

140

“A” Coal Flow KLB/HR

2 Hrs

“A” C/A Temperature

135AUTO

13071.2%0

200

2 Hrs

“A” Primary Air Flow KLB/HR

120

220

2 Hrs

“A” Sec. Air Flow (Total)

400

900

2 Hrs

Any Seal Air blower stopped

No coal on feeder belt

Any Pulv group trip not reset

Lube oil press low

Flame det clg air press lo

Flame detectedMin boiler A.F. required

LTR atom air press low

Pulv seal air diff press low

Feeder inlet gate not open

LTR oil press low or HDR VLV not open

All PA fans stopped or PAH stopped

Sequence Blocked By:

Diff-P

72.1AUTO

70.070.1%

H.Dmp %Amps

50.0CAS

49.0%48.0%

Damper %

31.0AUTO

30.027.8%

C.Dmp %

Start Pulv

Start Feeder

Pulv Tmp to Auto

Rel Sec Air

Stop Ltrs

Rel Pul DmdReady

Ready

Open Swg Vlvs

IG HDR VENT

10.7 45

50%CAS50%56%

N Damp S. Damp

Ready

Ready

Ready

Ready

DoneStatus

Begin Sequence

Sec Air to L.O.

Start Ltrs.

Pulv Grp Dmd

Start PA Flow

OPENOPENOPENOPENOPENOPENSWG Valves

NORMMNT-BNORMNORMNORMNORMMaint Mode

OFFOFFOFFOFFOFFOFF

ON

A7A6A5A3A2A1Flame

Main Flame

IgniterFlame

Fuel Type:Gas-1

90

30 30 30 30 30 30

DoneStatus

Air-N Air-S

XX

X

50%CAS50%42%

312 312

88 90 91 91 94ON ON ON ON ON

113.0AUTO115.0

75.0%

KLBH

205.0AUTO200.0

65.0%

615.2AUTO600.0

60.0%

Flow

X

Ready

HOLDPTR Status OK

Flame Status OK

Trip Status OKCLOSED

IG GAS TRIP CLOSED

IG OIL TRIP CLOSED

BURNER VENT CLOSED

KLBH °F

Main Menu Runback 1/2 L3 Feeder BPulv Overview L3 Flame L3 Gas C D E F G H

PULV “A”Group Trip

PULV “A”Trip Valves

PULV “A”Start Sequence Status: STARTING STOP

Reserved Faceplate

Zone

When any item on the screen is selected, the faceplate for that item appears in this reserved area.

All control manipulation is accomplished through the standardized faceplates.

RESET

RESET

RESET

Open SwgValves

Figure 4: Level 2 Pulverizer Control

Page 9: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 7© PAS Global, LLC 2017

Rather than using the three separate graphics shown to control each pulverizer (24 graphics

total), a single Level 2 graphic for each pulverizer was created with everything needed to

accomplish all typical control manipulations.

While complex in appearance to the layman, the trained operator had no difficulty in

understanding and accessing everything they needed for pulverizer startup, shutdown, and swap

situations that arose during the test. Much of the text on the screen has to do with the status of

existing semi-automated sequences that sometimes require operator intervention. Everything

on the screen is selectable, and when selected the standard faceplate for the element appears

in a reserved “faceplate zone” rather than floating around the screen obscuring the graphic.

Element manipulation is made via the faceplate.

Abnormal Situation Response Graphics The operator response for many abnormal plant situations is to cut rates by half, from 700MW

to 350MW. Called a “Runback,” this is a complicated and stressful procedure that takes about

20 minutes to accomplish. If done incorrectly or if important parameters are missed, the plant

can fall to zero output, a very undesirable situation. One of the main purposes of the simulator

was to periodically re-train the operators for this situation. The operators have to use more than

a dozen of the existing graphics to accomplish the task, involving a lot of navigation activity

around screen callups and dismissals along with control manipulation.

However, in more than a decade of such training, it had never occurred to anyone to design

special graphics specifically designed to assist in this task. This demonstrates the power of

inertia in dealing with our HMIs. Specific Abnormal Situation Detection and Response graphics

are an important element of an HPHMI.

PAS created two “Runback” graphics designed specifically to assist in this task. Every element

that the operator needed to monitor and control the runback situation effectively was included

on them. In use, the operators placed them on adjacent physical screens. Figure 5 shows

“Runback 1;” Runback 2 was similar. The reserved faceplate zone is on the lower right.

As a simple example of providing information rather than data, consider the trend graph at the

upper left of Runback 1. To be successful, the rate of power reduction must not be too slow or

too fast. The existing graphics had no trend of this, simply showing the current power megawatt

number. This new trend graph had the “sloped-line” element placed next to it, indicating the

ideal rate of power reduction, the full load zone, and the target half-rate zone. On the figure,

the actual rate of drop is initially exceeding the desired rate, and that condition is easily seen.

(Note: It would have been more desirable to have the sloped lines on the background of the

trend area itself, but the DCS could not accomplish such a depiction. This is a compromise, but

one the operators still found to be useful.)

Page 10: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 8© PAS Global, LLC 2017

The Testing Eight Operators, averaging eight years of console operating experience each, were used in the

test. They received only one hour of training with the new graphics prior to the start of testing.

(This was to address the common objection of “Changing our graphics would take months of

retraining!”) They were tested on four increasingly complex situations, each lasting about 20

minutes.

● Coal Pulverizer Swap Under Load

● Pulverizer Trip and Load Reduction

● Manual Load Drop with Malfunctions

● Total Plant Load Runback

All operators did all scenarios twice, using the old graphics alone, and the HPHMI graphics. Half

used the old graphics first (without having been shown the new graphics), and half used the

new HPHMI graphics first.

Quantitative and qualitative measurements were made on the performance of each scenario

(e.g., detection of the abnormal condition, time to respond, correct and successful response).

11-13-2012 14:22:09

Gross MW562

700

600

350

300

750

-0.50

30005

20 Min

MainSteam

psig2400

Furn Pres

in.H2O-0.5

20 Min

0

8

20 Min

In.hg

LPT-A3.2

LPT-B3.0

In.hg

UNIT 2: RUNBACK Graphic 1

Sec Airin.H2O

EconO2 %

Aux Stmpsig

Gross MW 562

TRICON DEMAND:

ACS DEMAND:

100.0%

100.0%Input new ACS DEMAND or use buttons:

90.0%

TRICON LOAD RATE:

VERYFAST

TURBINE MASTER MAN

TURBINE FOLLOW

BOILER FOLLOW

COORD CONTROL

CONSTANT PRESSURE

VARIABLE PRESSURE

75001020

20 min000

Econ O2%

5.0

Sec Air

in.H2O7.0

AirKLBH

7400

400

Reserved Faceplate Zone

When any item on the screen is selected, the faceplate for that item appears in this reserved area.

All control manipulation is accomplished through the standardized faceplates.

Main Menu Runback 2 BPulv Overview C D E F G HA

7.1

0.2 0.2

LPT-Ain.hg

LPT-Bin.hg

300

Turb-X1Mills

300

Turb-X2Mills

10

DrumTop>Bot °F

3.1 3.1

A2BPFT

B2BPFT

-0.5

Furnin. H2O

3001000

ReheatdegF

10002400

Main SteamdegFpsig

5.07.0

A/FRatio

Auto7.050%

Auto5.050%

Boiler Master

65.12402

FuelMaster

Auto220050%

Auto65.048%

DecreaseLoad

IncreaseLoad

Figure 5: Abnormal Situation Graphics – Runback 1

Page 11: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 9© PAS Global, LLC 2017

The ResultsThe High Performance graphics were significantly better in assisting the operator in:

● Maintaining situational awareness.

● Recognizing abnormal situations.

● Recognizing equipment malfunctions.

● Dealing with abnormal situations.

● Embedding knowledge into the control system.

Operators highly rated the Overview screen, agreeing that it provided highly useful “big picture”

situation awareness. Even with only one hour of familiarization with the new graphics, operators

had no difficulties in operating the unit. The High Performance graphics are designed to have

intuitive depictions.

Very positive Operator comments were received on the analog depictions, alarm depictions,

and embedded trends. There were consistent positive comments on how “obvious” the HPHMI

made the various process situations. Values moving towards a unit trip were clearly shown and

noticed by the operators.

The operators commented that HPHMI would enable faster and more effective training of

new operations personnel. The negative operator comments generally had to do with lack of

familiarity with the graphics prior to the test (which was intentional).

The best summary quote was this one:

“Once you got used to these new graphics, going back to the old ones would be hell.”

The effect of inertia being the controlling factor for HMI change was once more confirmed.

The existing HMI had been in use since the early 1990s, with simulator training for more than a

decade. Despite clear deficiencies, almost no change to the existing HMI had been made since

inception.

Operators using the existing graphics first in the test were then asked “What improvements

would you make to the existing graphics to help in these situations?” In response, there were

very few or no suggestions!

However, operators using the existing graphics after they used the HPHMI graphics had many

suggestions for improvement, namely analog depictions, embedded trends, alarm depiction,

consistent navigation, etc.

So, people get “used to” what they have – and do not complain or know what they are missing

if they are unfamiliar with these HPHMI concepts.

A lack of complaints does not indicate that you have a good HMI!

Page 12: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 10© PAS Global, LLC 2017

PowerGraphiX®

After the publication of The High Performance HMI Handbook, Southern Company, a major

United States power generation and distribution company, took notice of it. Southern Company

operates more than 280 nuclear, coal, oil, gas, biomass, wind, solar, and hydro generating units

at more than 75 power plants, with a combined capacity of more than 45,000 megawatts. They

are well known for their forward thinking and engineering approach to problem solving.

Southern had traditionally designed graphics much like others have. This was either using the

perspective of an engineer looking at the P&IDs, or by delegating graphics creation to operators,

who tended to arrange screens of numbers suiting their individual preferences. Neither of those

approaches led to a consistent or satisfactory end product.

In 2009, Southern suspected that there “had to be a better way” to present information to their

operators. Significant problems were being found as new projects were each being treated

as custom HMI implementations. Existing control rooms had significant screen and graphic

proliferation – with many plants having more than 500 different graphics used for control and

creating significant HMI maintenance problems.

An in-house study was made and identified these common deficiencies:

● Few internal standards were in place.

● Personal graphic preferences resulted in each control project being a custom,

inconsistent solution.

● Large HMI inconsistencies existed between identical plants.

● Significant retraining was required for personnel transfer.

● The over-abundant use of color incorporated in their graphics was not an aid to

the operator.

● Individually plant-customized graphics led to significant impacts to cost, schedule,

and consistency.

Southern concluded that the graphics portion of a controls project should be an “engineered

solution,” just like the rest of the project. After considerable research, they recognized that the

principles and design practices covered in The High Performance HMI Handbook dealt with all

the issues they identified and went beyond them. Managerial support of a major improvement

Figure 6: Original Control Room and How it Grew After DCS Conversion

Page 13: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 11© PAS Global, LLC 2017

effort was obtained. A test case project was chosen, involving a DCS conversion for two coal-

fired generation units. HPHMI Workshops were held and workgroups formed. Corporate-wide

operations experts designed template Level 1 and 2 graphics based on task analysis. The screen

layout was driven by the Operator’s thought processes. The goal was total fleet standardization

of High Performance graphics.

The test project was successful and then further proven in 17 plant conversions with more

underway. Operator response is positive:

● “I can see problems coming before they happen.”

● “You got it right.”

● “I didn’t like it at first, but I do now.”

● “I wish I had this when I was learning to operate.”

● “I can find what I need now.”

● “I don’t have to jump around between screens to operate.”

The number of graphics used to control a plant was reduced from a typical value of 300-600 to

approximately 80. Southern Company has documented both performance improvements and

substantial costs savings in these areas:

● Improved operator situation awareness.

● Improved abnormal situation detection and handling.

● Reduced engineering time and cost for new plants, conversions, and

modernizations.

● Reduced hardware costs (fewer workstations).

● Reduced licensing cost for control system software.

● Reduced ongoing maintenance cost.

● Reduced ongoing cybersecurity cost (fewer workstations and licenses).

● Reduced training costs.

● Upsets avoided (anecdotal evidence and cases).

Now designated as PowerGraphiX®, these graphics represent thousands of hours of design,

improvement, and actual in-operation experience. The measurements and statuses shown on

each graphic have received highly detailed review and proof testing by experienced power

Figure 7: Control Room after HPHMI Implementation of PowerGraphiX®

Page 14: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 12© PAS Global, LLC 2017

industry experts. The designs, layouts, and functionalities are the right choices for implementation

of a proper graphic hierarchy and HPHMI. They support maximum functionality for effective

operator monitoring and control.

The power generation industry is much more consistent in plant design than is the petrochemical

/ chemical industry. This makes it possible for advancements such as PowerGraphiX to be

incorporated much more easily and inexpensively by other companies. Southern and PAS

realized that making PowerGraphiX available to the power industry would benefit overall

operational effectiveness as well as safety.

To that end, PAS provides PowerGraphiX to the power industry. Here are a few of the many

features and benefits included in PowerGraphiX.

Features:

● Documented HMI Philosophy & Style Guides.

● Layouts and templates for Hierarchy Levels 1, 2, 3, & 4.

● Object Libraries.

Benefits:

● Reduced engineering time and cost (Note that it costs at least as much to

build or migrate a bad graphic as a good one.)

● Improved control system HMI consistency.

● Improved operator situation awareness and effectiveness.

● Effective use of large screen displays.

● Reduced ongoing HMI maintenance cost.

● Reduction in number of graphics.

These platforms are initially supported, and more are being developed. All product names are

property of their respective owners and used in this paper for identification purposes only:

● ABB Symphony Plus ®

● Emerson Ovation ®

● Emerson Delta-V ®

● Invensys FOX IA ®

● Honeywell Experion ®

● Alstom Alspa 6 ®

Plant Types:

● Coal Fired.

● Combined Cycle.

● Supercritical.

For more information on PowerGraphiX, visit www.pas.com/PowerGraphiX or email at info@

pas.com.

Page 15: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 13© PAS Global, LLC 2017

Paradigm Busting: The Pipeline OverviewThis is an example of the kind of out-of-the-box thought process involved in re-examination

of some of our HMI paradigms. The pipeline industry (including the water and wastewater

segment) typically involves a process network of pipelines and processing facilities spread over

large geographical area.

That industry has the typical P&ID-

covered-in-numbers approach to

graphics involving the facilities.

They also have usually developed

an “Overview” type of display.

The paradigm for that is as shown

in Figure 8, a map covered in

numbers. By now, you should

have guessed this!

Certainly some geographic detail

is relevant to the role of the

operator in this case. But is all of

this detail relevant or helpful? Or is it a distraction? Is a map covered in numbers any better than

a P&ID covered in numbers? The question is – what would be better?

It is a great tradition in engineering to build on the work of others – to adapt and enhance

concepts that are successful in other domains. The trick is to have a wide enough view of

the topic to recognize an applicable

solution. It is to ask, “Has anyone else

solved a similar problem?” In this case,

the answer is yes, and in a big way.

A map of the very complex 1908

London Underground subway system

is shown in Figure 9.

11.55

12.44

42.87

21.43

32.17

31.4127.81

40.56

38.33

18.48

60.02

2.34

17.36

29.927

Figure 8: A Typical Pipeline Network Overview Display

Figure 9: The 1908 London Underground Map

Page 16: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 14© PAS Global, LLC 2017

The user of this map is the subway rider. It is not that easy to interpret, for the purpose of

figuring out the best route from your current position to the destination, using which subway

lines, and changing at which stations. And there is time pressure – you are looking at the map,

and the train has just pulled in next to you. Do you get on this one or the next one? Hurry!

It took about three decades for something better to be produced. In 1936, Engineer Harry Beck

came up with a radically different depiction. He determined these questions to be the key ones

for the subway rider:

● Where am I now (what station)?

● Where am I going (what station)?

● What lines service this station and where do they go?

● Where do I change trains?

● How many stops until my destination?

Even more importantly, he realized that there were many things that the subway rider did not

need to know:

● Am I going around a curve?

● Am I passing under a river or near another train line?

● What is the relative distance between stations?

● Am I traveling in a specific direction (N,S,E,W) in between stations?

Beck realized that depicting topology, and not geography, was the key.

In the revised map, every line is horizontal, vertical, or at 45 degrees – even the River Thames.

There is just enough geography and landmark depiction for the rider to orient their current

position and find their destination station. It is fast and easy to pick out an efficient route, even

for the novice rider.

Since 1936, the London

Underground has continued to

grow in complexity, but Beck’s

Paradigm still works. It has become

an iconic image, so functional that

it has been universally adopted.

How can this paradigm be adapted

to a Level 1 Overview display for

a pipeline network? There are

geographic cues important to a

pipeline operator.

Figure 10: Harry Beck’s 1936 London Underground Map

Page 17: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 15© PAS Global, LLC 2017

For example, the location of a station or spill relative to state lines can mean that different

regulations, reporting requirements, or emergency procedures apply.

Task analysis has shown these to be some important things for depiction:

● Important status conditions and alarms.

● Significant highway crossings.

● Significant waterway crossings.

● Neighborhoods if adjacent to pipeline.

● Important boundaries (i.e., state lines).

● Pressure profiles.

● Analog indicators showing station performance.

● Direction and content indicators.

● Important trends.

● Topology, not geography.

A conceptual Pipeline Overview Display with these elements is shown in Figure 11.

HMI design is not simply arranging objects from a library onto a screen. There is room for a

creative approach, as long as the proper principles are reflected in the design. When faced with

an unusual process depiction problem, look at how similar situations have been solved in other

areas, and then adapt them.

Figure 11: A Conceptual Pipeline Overview Display

Altair 4

228 660 112 156 302 670 125 212

TX LAAltair 4

Mesklin

Trantor

Minbari

Arrakis

River

Terminus

Gateway

Line Pressure ProfilesKessel RunFrostbite FallsFra MauroBrigadoonCannonballMayberry 665 630 627 615 609 592 560 545 523 481

Leaks

OKOKOKOKOKOK

MCFH psi °F

C1 OK C2 OKC3 OK C4 OKI

C1 I

C2 I

C3 I

C4

12

34

12

34

12

34

C1 OK C2 OKC3 Fault C4 OK

C1 OK C2 OKC3 OK C4 OK

OutletscfhVent

MCFH psi °F Outlet

scfhVentC1 C3

Mesklin

259 635 133 115 202 558 110 108

MCFH psi °F

C1 OK C2 OKC3 OK C4 OKI

C1 I

C2 I

C3 I

C4 Outlet

scfhVent

MCFH psi °F Outlet

scfhVentC1 C3

Arrakis

238 658 127 116 402 523 114 72

MCFH psi °F

IC1

IC2

IC3

IC4

OutletscfhVent

MCFH psi °F Outlet

scfhVentC2 C4

Trantor

218 675 108 126 302 453 104 61

MCFH psi °F

IC1

IC2

IC3

IC4

OutletscfhVent

MCFH psi °F Outlet

scfhVentC2 C3

Valve Positions

A11A12A13A14B11B12B13B14J2J7R4R5R6R7Z51Z52Z53

TotalFlow

600-60 -30-90 2 Hrs

1000

943MCFH

Weyland-Yutani Pipeline Overview

LV-426

Pixley

Cogswell

Raisa

Cernon

Dantooine

Hekate

12

34

Eddore

Tyrell LV-223

Hooterville

Cannonball

Fra Mauro

Kessel Run

Mayberry

Brigadoon

Frostbite Falls

GreenAcres

Pern

Rama

ChindiShadyRest

Bodine

Armstrong Aldrin

Prod

C57DJUP2RV12V35BC182C172

Alarms 1

TotalUn-Ack

0 1 4 20 0 1

Additives

Main Menu

CYCLE

3

2

3

3

2

2 S

3

Page 18: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 16© PAS Global, LLC 2017

A Review of HMI StandardsMany readers of this white paper will already have The High Performance HMI Handbook and

may be curious about other HMI-related documents. In this section, we review the API-1165

Recommended Practice and the ISA-101 HMI Standard released in August 2015.

We need to be precise in our language when discussing standards. In this section, the term

“standard” applies only to a document that is produced in documented accordance with a

strict methodology that involves balance of interests, consensus, and a stringent review and

documentation process. Recognized bodies like the ISA follow these principles in issuing

documents they call standards. Other organizations (e.g., EEMUA) do not, and the documents

they produce are essentially books and reports, not standards.

When standards are issued by a recognized body, they acquire the status of being a “recognized

and generally accepted good engineering practice (RAGAGEP).” This clumsy acronym denotes

something very important, because regulatory agencies can and will cite the principle of

RAGAGEP as being enforceable, as a “catch-all.”

Standards are highly restricted in their allowable content. Standards intentionally describe

the minimum acceptable and not the optimum. By design, they focus on the “what to do”

rather than the “how to do it.” Standards intentionally do not have detailed or specific “how-to”

guidance – the kind of guidance that most people actually want or need, but that we do not

want to be mandatory. Standards do not contain examples of specific proven methodologies or

detailed work practices.

Other than The High Performance HMI Handbook, and this much expanded white paper, there

are very few authoritative documents that address process control HMI. Here is a discussion of

two of them.

API-1165: Recommended Practice for Pipeline SCADA Displays

API documents are often considered as RAGAGEP by their regulatory agency, PHMSA (Pipeline

and Hazardous Materials Safety Administration). In 2006, API issued a document on SCADA HMI

displays. There are some significant inconsistencies within that document. Overall, the concepts

incorporated in the text portion of the document are valid. It mentions several good practices.

The examples provided, however, contain several depictions that are in direct violation of the

principles in the text.

Page 19: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 17© PAS Global, LLC 2017

For example, Section 8.2.4 states, “Color should

not be the only indication for information. That

is, pertinent information should also be available

from some other cue in addition to color such as a

symbol or piece of text.”

Yet throughout the remainder of the document,

examples are shown that routinely violate this

principle. Figure 12 shows only a few of the

“recommended practice examples” from API-

RP-1165. In many of these examples, only subtle

color differences, not distinguishable by a

substantial fraction of the operator population, are

the only means to distinguish a significant status

difference.

In one table, API-1165 recommends color coding

alarms by type. The well-known best practice is

that they are redundantly coded by priority, not

type.

Users of API-1165 are therefore advised to pay more

attention to the written principles it contains than

to the example depictions.

ISA-101 Human Machine Interfaces for Process Automation SystemsISA-101 (officially ANSI/ISA-101.01-2015) was begun in October 2008, very close to the time that

the first edition of The High Performance HMI Handbook was published. PAS is a voting member

of the ISA-101 committee. In June 2014, a “final” draft of ISA-101 was sent out to the overall

committee for final comment and ballot. The draft was approved by vote but 1,163 comments

were returned and had to be resolved. In March 2015, the version reflecting those modifications

was sent out for a revote, which passed and the document was released in August 2015.

Understand that the ISA document is much more about the “work process” of creating and

operating an HMI and not the details of what makes for a good vs. poor HMI. Those that are

looking for such detail will be disappointed.

The ISA-101 document is relatively short, containing approximately 44 pages of content and

approximately 20 pages of introduction, definitions, and legal notice.

Figure 12: Sub-optimal Examples from API-RP-1165

State Background

ColorForeground

Color Example

Normal Black Green 1234

High-High Alarm Black Red 1234

High Alarm Black Yellow 1234

Low Alarm Black Yellow 1234

Low-Low Alarm Black Red 1234

Unknown Error Black Blue 1234

Page 20: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 18© PAS Global, LLC 2017

ISA-101 contains consistent definitions of various aspects of an HMI. It has the typical text

principles of good graphics design, but these are constrained by what is allowable in a standard.

Standards are to provide the minimum acceptable, not the optimum. For example, ISA-101 can

make a statement like “Color should be used to direct attention and add meaning to the display.”

But ISA-101 does not contain anything like the example color palette of Figure 10 in this paper

(Part 1), nor should it. Such detail is not within the purview of a standard.

ISA-101 follows the usual Life Cycle approach of other ISA Standards. Life Cycle is a document

structure, not a project plan. An example of a Life Cycle for HMI development and operation is

supplied. It is mandatory to use some sort of life cycle process to administer an HMI. But the life

cycle shown in the document is labeled as an example and is not mandatory.

ISA-101 also makes it mandatory to place changes in the HMI under Management of Change

(MOC) procedures, similar to those that govern other changes in the plant and the control

system. The details of the MOC procedures are left to the user.

A reader with only brief and rudimentary knowledge of control systems and process control

HMI will find nothing new or unusual in ISA-101.

ISA-101 makes it mandatory to create “System Standards.” These are documents that govern the

design and creation of the HMI. These are the familiar HMI Philosophy, Style Guide, and Toolkit

(Object Library). It is mandatory to apply MOC to the Toolkit. ISA-101 has discussion of ways to

create these documents, but there are no examples. Brief descriptions of the contents of such

documents are provided (See the end of this white paper for a detailed Table of Contents listing

of a comprehensive HMI Philosophy and Style Guide). It is noted that the primary user of the

HMI is the operator and design should keep that in mind. There is a small bit of guidance about

the use of scripting logic and color.

DESIGNSYSTEM STANDARDS

OPERATEIMPLEMENT

CONTINUOUS WORK PROCESSES

Continuous Improvement

REV

IEW

Philosophy

Style Guide

Toolkits

In Service

Maintain

Decommission

Continuous Improvement

Build Displays

Build Console

Test

Train

Commission

Verification

Console Design

HMI System Design

User, Task, Functional

Requirements

Display Design

New DisplayDisplay Changes

New SystemMajor Changes

ENTRYENTRY

MOC Audit Validation

Figure 13: ISA-101 Example Life Cycle

Page 21: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 19© PAS Global, LLC 2017

There is a brief section on the determination of the tasks that a user will accomplish when using

the HMI and how those feed the HMI design process.

The activities listed in the ISA-101 life cycle are generally discussed in bullet list and table form.

It contains basic (and well known) recommendations such as these:

● The HMI should be consistent and intuitive.

● The information shown should be relevant to the operator.

● Color should not be the only indicator of an important condition.

● Colors chosen should be distinguishable by the operators.

● Auditory warnings should be clear and unambiguous.

There are no examples of proper and improper human factors design and no details such as

appropriate color palettes or elements. The only HMI examples in ISA-101 are in a survey-type

section providing a list of different types of display styles. Each style is accompanied by a small,

intentionally non-detailed example, typically of about one square inch in size. Figure 14 shows

a few of those examples in their actual sizes.

ISA-101 mentions the concept of display hierarchy with discussion of Level 1, 2, 3, and 4 displays.

Each has an example, and those have been made intentionally undetailed and simplified. The

descriptions of the different levels contain no unusual items. Here, for example, are the ISA-101

Level 1, 2, and 3 display examples.

The reader is invited to compare these to Figures 33, 34, and 35 in Part 1 of this white paper.

Figure 14: ISA-101 Example Images, Full Size

Page 22: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 20© PAS Global, LLC 2017

ISA-101 finishes by providing brief descriptions of the following methods for interacting with an

HMI.

● Data entry in fields.

● Entering and showing numbers.

● Entering and showing text.

● Entering commands.

● Designing buttons.

● Using faceplates.

● Navigation – various common methods for navigating from one graphic to another

are discussed, such as hierarchical menus and navigation buttons.

● User access and security are briefly mentioned.

In ISA-101, user training in use of the HMI is mandatory. There is brief discussion of a list of things

that the training should cover, such as interpreting screen symbols, manipulating the controls,

and navigating from screen to screen. If non-operators are also expected to use the HMI, they

are expected to be trained as well.

Figure 16: ISA-101 Example Level 2 Graphic

Figure 15: ISA-101 Example Level 1 Graphic

Page 23: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 21© PAS Global, LLC 2017

In summary, the publication of ISA-101 is an important step in the field of HMI. ISA-101 is a short

document containing some generally well-known and basic principles of HMI design. Its only

mandatory requirements are to have an HMI Philosophy, Style Guide, and Object Library, to

apply MOC to the HMI, and to provide for user training. ISA-101 contains no detailed examples

and does not provide detailed design guidance. For those, the reader will need to seek other

sources of expertise. ISA plans to create additional “Technical Reports” on ISA-101, but these

typically take from two to six years to publish.

The PAS Seven Step HPHMI Work ProcessThere is a seven step methodology for the development of an HPHMI with more detail in The

High Performance HMI Handbook.

Step 1: Adopt a High Performance HMI philosophy, Style Guide, and Object Library. You must

have a written set of principles detailing the proper way to construct and implement a

High Performance HMI.

Step 2: Assess and benchmark existing graphics against the HPHMI philosophy. It is necessary

to know your starting point and have a gap analysis.

Step 3: Determine specific performance and goal objectives for the control of the operation

and for all modes of operation. These are such factors as:

● Safety parameters/limits.

● Production rate.

● Run length.

Figure 17: ISA-101 Example Level 3 Graphic

Page 24: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 22© PAS Global, LLC 2017

● Efficiency.

● Equipment health.

● Environmental (i.e., emission control).

● Production cost.

● Quality.

● Reliability.

It is important to document these along with their goals and targets. This is rarely

done and is one reason for the current poor state of most HMIs.

Step 4: Perform task analysis to determine the control monitoring and manipulations needed

to achieve the performance and goal objectives. This is a simple step involving

the determination of which specific controls and measurements are used to

accomplish the operation’s goal objectives. The answer determines the content of

each Level 2, 3, and 4 graphic.

Step 5: Design High Performance graphics using the design principles in the HMI philosophy

and elements from the style guide and object library to address the identified tasks.

Step 6: Install, commission, and provide training on the new HMI.

Step 7: Control, maintain, and periodically reassess the HMI performance.

HPHMI Implementation on a BudgetWhile desirable, it is not necessary to replace all (or any) of your existing graphics to obtain

much of the benefit of HPHMI. A partial implementation can provide most of the benefits with

minimum disruption. A partial implementation involves:

● ALL EXISTING GRAPHICS ARE KEPT ON THE SYSTEM. This eliminates almost all

objections to HMI improvement.

● Design and deploy new Level 1, Level 2, and Abnormal Situation Management

graphics designed with HPHMI principles. This is generally around 20 or so

graphics.

● Existing graphics can be designated as Level 3 (which is generally what they

actually are) and navigation paths to them altered.

● Improvements to those existing Level 3s (correcting color choices, adding status

indications, adding embedded trends, and providing proper context) can be made

over time as desired. Yes, there will be inconsistency between the HPHMI graphics

and the existing ones. But in examining hundreds of existing HMIs, we have yet to

find one that did not already have significant inconsistencies within itself.

Operators can handle this with no problem.

Page 25: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 23© PAS Global, LLC 2017

Experience has shown that the operators will begin to use the High Performance Level 2

graphics preferentially for normal operation and abnormal situation detection. Why? Because

they are BETTER for the purpose. They will use the existing Level 3 graphics for the detailed

troubleshooting purposes that they are most suited to support.

Any facility can afford about twenty new graphics! A High Performance HMI is affordable.

ConclusionThe most important job of an operator is to detect and successfully respond to an abnormal

situation. The HMI is the means by which the operator accomplishes this task. Existing HMIs

are woefully inadequate for this purpose. They were generally designed in an era when proper

practices were unknown, and the resistance to change has kept those graphics in commission

for two or more decades.

The principles of High Performance HMI are specifically developed to deal with the needs of

today’s operators and the complex systems they manage. A High Performance HMI is designed

to be the best tool for operator interaction with the process control system. It is designed with

these important capabilities in mind:

● Provision of an easily monitored overview of the equipment under the

operator’s control.

● Ease in maintaining full situation awareness of the span of a

large process.

● Early detection and clear depiction of abnormal conditions.

● Effective resolution methods for abnormal situations.

● Embedding easily accessible and relevant knowledge into the control system.

The benefits of such an HMI are more than just reducing human error and avoiding abnormal and

unsafe operations. The HMI becomes an effective operational tool for maximizing production,

reliability, efficiency, quality, and profitability.

Industry is now recognizing the need and benefits of improved HMIs. Dozens of major companies

are in the process of HMI modernization and see it as not only a safety initiative, but a cost-

saving and productivity-enhancing one as well.

The functionality and effectiveness of our process automation systems can be greatly enhanced

if redesigned in accordance with proper HMI principles. A High Performance HMI is both practical

and achievable.

Page 26: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 24© PAS Global, LLC 2017

Typical Table of Contents of an HPHMI Philosophy and Style GuideHigh Performance HMI Philosophy Example Table of ContentsNote: All sub-sections are not shown.

1.0 Introduction

1.1 Purpose and Use of a High Performance HMI Philosophy

1.2 Purpose and Function of the Operator HMI

1.3 Common but Improper HMI Practices

1.4 Functional Description of HMI Elements

1.5 Level 1 Process Area Overview Display

1.6 Level 2 Process Unit Control Display

1.7 Level 3 Process Unit Detail Display

1.8 Level 4 Process Unit Support Display

1.9 Special Purpose Graphics for Specific Abnormal Situations

1.10 Display Content

1.11 Display Layout

1.12 Display Navigation

1.13 Alarm Management Features

2.0 HMI Design Process

2.1 Step 1 - Adopt a High Performance HMI Philosophy, Style Guide, and Object

Library

2.2 Step 2 - Assess and benchmark existing graphics against the HMI Philosophy

2.3 Step 3 - Determine specific performance and goal objectives for the control of

the process

2.4 Step 4 - Perform task analysis to determine the control manipulations needed

to achieve the Performance and Goal objectives

2.5 Step 5 - Design and build High Performance Graphics using the design

principles in the HMI Philosophy and elements from the Style Guide and

Object Library, to address the identified tasks

2.6 Step 6 - Install, commission, and provide training on the new HMI

2.7 Step 7 - Control, maintain, and periodically reassess the HMI performance

3.0 Purpose and Use of an HMI Style Guide and Object Library

3.1 DCS Specificity

3.2 Object Library Contents and Usage

4.0 HMI Performance Monitoring and Ongoing Assessment

5.0 HMI Management of Change (MOC) and Maintenance

6.0 Control Room Factors

6.1 Control Room Design Factors

6.2 Control Room Work Practices

6.3 Operator Console Design

6.4 Operator Work Practices

6.0 References

Page 27: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 25© PAS Global, LLC 2017

High Performance HMI Style Guide Example Table of ContentsNote: All sub-sections are not shown.

1.0 Purpose and Use of an HMI Style Guide

2.0 Control System Specificity

3.0 HMI Development Work Process

4.0 Object Library – Description and Use

5.0 Display Concepts, Objectives, and Content

5.1 Level 1 Display – Process Overview

5.2 Level 2 Displays – Process Unit Operating Graphics

5.3 Level 3 Displays – Process Detail Displays

5.4 Level 4 Displays – Process Support and Diagnostic Displays

6.0 Global System Display Defaults

7.0 Operator Interaction Methodologies

7.1 Standard DCS Functionality Usage

7.2 Change Zones and Faceplates

7.3 Standard Display Templates

7.4 Point Manipulation and Faceplates

7.5 Window Management and Yoking

8.0 Display Layout

9.0 Navigation Methods and Practices

9.1 Programmable Buttons and Keys

9.2 Keyboards, Menus, and Tab-based Navigation

9.3 Target-Based Navigation

9.4 Pointing and Selection Devices

10.0 Basic Principles of Process Depiction

10.1 The Proper Role of the P&ID View Element

10.2 High Performance Display Elements

11.0 The Proper Use, Implementation, and Importance of Trends

12.0 Color Palette and Usage

12.1 Color Palette Definitions & Settings

12.2 The Role of Color in Situation Awareness

12.3 Designing for Color-Deficiencies: Coding Redundancy

13.0 Detailed Display Element Specification and Functionality

13.1 Depiction of Lines and Labeling

13.2 Depiction of Static Text, Lists, Tables, and Similar Structures

13.3 Vessels and Other Static Equipment

13.4 Depicting Dynamic Equipment

13.5 Depicting Analog and Digital Values

13.6 At a Glance Performance Indicators

13.7 Depicting Controllers

13.8 Device Position Feedback

13.9 Vessel Liquid Levels

13.10 Depiction of Point Names

Page 28: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 26© PAS Global, LLC 2017

13.11 Temperature, Pressure, and Similar Profiles

13.12 Startup and Checklist Elements

13.13 Plan vs. Actual

13.14 Depicting Economic Constraints

13.15 Production Extrapolation

13.16 Dynamic Shapes and Elements Library

13.17 Data Input Mechanisms and Safeguards

13.18 Shutdown Activation Elements

13.19 Depicting Valves and Other Final Control Elements

13.20 Interlock and Logic Elements and Displays

14.0 Display Naming Convention & File Storage Naming/Pathnames

15.0 Alarm Functionality

15.1 Proper Configuration of the Alarm Summary Display

15.2 Proper Depiction of Alarms

15.3 Proper Settings for Audible Alarm Tones

15.4 Abnormal Condition Indications

15.5 Alarm Management Functionality

15.6 Alarm and Graphic Association

15.7 Operator Alarm Response

15.8 Depiction and Alarming of Instrument Malfunction

15.9 Alarm Shelving Depiction and Functionality

15.10 State-Based Alarming

15.11 Alarm Flood Suppression

15.12 Operator Alert System

16.0 Special Purpose Graphics

16.1 Startup and Shutdown Assistance

16.2 Expected Abnormal Situations

16.4 Product Change

16.5 Geographic Screens

17.0 Depiction of Programmatic Functionality

18.0 Display Call-up Speed and Performance Requirements

19.0 Advanced Process Control (APC) Application, Functionality, and Depiction

20.0 Standardized Abbreviations List and Engineering Unit Descriptors

21.0 Standard Tools and Display Creation Methodologies

22.0 System Backup

23.0 Management of Change

24.0 Standardized Abbreviations and Engineering Unit Descriptors

Page 29: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 27© PAS Global, LLC 2017

About the AuthorsBill R. Hollifield, PAS Principal Alarm Management and HMI Consultant

Bill is the Principal Consultant responsible for the PAS work processes and

intellectual property in the areas of both Alarm Management and High

Performance HMI. He is a member of the American Petroleum Institute’s API

RP-1167 Alarm Management Recommended Practice committee, the ISA SP-

18 Alarm Management committee, the ISA SP101 HMI committee, and the

Engineering Equipment and Materials Users Association (EEMUA) Industry

Review Group.

Bill has multi-company, international experience in all aspects of Alarm Management and HMI

development. He has 28 years of experience in the petrochemical industry in engineering and

operations, and an additional 12 years in alarm management and HMI software and services for

the petrochemical, power generation, pipeline, pharmaceutical, and mining industries.

Bill is co-author of The Alarm Management Handbook, The High Performance HMI Handbook, and

The Electric Power Research Institute (EPRI) Guideline on Alarm Management.

Bill has authored several papers on Alarm Management and HMI, and is a regular presenter on

such topics in such venues as API, ISA, and Electric Power symposiums. He has a BSME from

Louisiana Tech University and an MBA from the University of Houston. In 2014, Bill was made an

ISA Fellow.

Hector R. Perez, PAS High Performance HMI Product Manager

Hector oversees the High Performance HMI business line at PAS. He is a

chief designer of High Performance graphics intended to facilitate situation

awareness in a variety of industries. At PAS, Hector oversees PAS software

directions to improve product design and capabilities.

Prior to working with PAS, Hector was a senior engineer at Schlumberger. His

strength in design contributed to his success in creating new and improved

HMIs for reservoir evaluation services and interfaces for business Key

Performance Indicator tracking.

In addition to his expertise in High Performance HMI, Hector has widespread experience in all

aspects of Alarm Management. He has facilitated numerous Alarm Management workshops,

conducted alarm rationalization projects, and developed Alarm Philosophy documents for a wide

range of clients in the petrochemical, power generation, pipeline, and mining industries.

Hector has authored technical articles on High Performance HMI. In 2009, he and Bill collaborated

with the Electrical Power Research Institute (EPRI) on a comparative research study evaluating

High Performance graphics and operator effectiveness. Hector holds a Bachelor of Science in

Chemical Engineering from Rice University.

Page 30: Maximize Operator Effectiveness papers... · the ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems released in August 2015. HPHMI Work Processes and Implementation

High Performance HMI 3.0 - Part 2 | Page 28© PAS Global, LLC 2017

About PAS

PAS Global, LLC is a leading provider of software solutions for process safety, cybersecurity, and

asset reliability to the energy, process, and power industries worldwide. PAS solutions include

industrial control system cybersecurity, automation asset management, alarm management, high

performance HMI, boundary management, and control loop performance optimization. PAS

solutions are installed in over 1,000 facilities worldwide with more than 40,000 users.

For more information, visit www.pas.com.

Connect with PAS on Twitter @PASGlobal or LinkedIn.

© PAS Global, LLC 2017. Ideas, solutions, suggestions, hints and procedures from this document are the intellectual property of PAS Global, LLC and thus protected by copyright. They may not be reproduced, transmitted to third parties or used in any form for commercial purposes without the express permission of PAS Global, LLC.

ReferencesAPI-RP-1165: Recommended Practice for Pipeline SCADA Displays, American Petroleum Institute

(2006)

Crawford, W., Hollifield, B., Perez, H., Electric Power Research Institute Operator HMI Case Study:

The Evaluation of Existing “Traditional” Operator Graphics vs. High Performance Graphics in a

Coal Fired Power Plant Simulator, Product ID 1017637 (2009)

Hollifield, B. Oliver, D., Nimmo, I., and Habibi, E., The High Performance HMI Handbook. PAS (2008)

Hollifield, B. and Habibi, E. 2006. The Alarm Management Handbook, 2nd edition. PAS (2010)

ANSI/ISA-101.01-2015: Human Machine Interfaces for Process Automation Systems, International

Society for Automation, August 2015