Nasby (2017) - High Performance HMIs For More Effective Operations

Using ISA-101 &
High Performance HMIs for

More Effective Operations
(Slide Deck for Distribution)
Speaker: Graham Nasby

Standards Voting member of ISA-101 Committee
Certification
Education & Training
Publishing
Conferences & Exhibits WEAO Intelligent Wastewater Systems Seminar
Using ISA-101 & High Performance HMIs – summary slides
Sept 14, 2017 – Canada Centre for Inland Waters – Burlington, Ontario
WEAO Intelligent Wastewater Systems Seminar – Sept 14, 2017
About the Speaker
Graham Nasby, P.Eng., PMP, CAP
• Water SCADA & Security Specialist

• City of Guelph Water Services
• 10 years in the consulting sector, followed by 2 years at the city
• WEAO and OWWA Member, Member of OWWA Automation Committee

• Co-chair of ISA112 SCADA Systems standards committee
• Voting member of ISA101 HMI Design standards committee
• Voting member of ISA18 Alarm Management standards committee
• Named Canadian Expert on IEC/SCC-TC65 with Standards Council of Canada
• Has published over 30 papers and articles on automation topics

• Received University of Guelph “Mid Career Achievement Award” in 2014
• Named ISA’s technical division leader of the year award in 2013.
• Contact: graham.nasby@guelph.ca

WEAO Intelligent Wastewater Systems Seminar – Sept 14, 2017 2
First a Few Acknowledgements
• Thanks to my fellow members of the ISA-101 committee for contributing several of the graphics in this
presentation
• Also special thanks to Bill Hollifield, author of the High Performance HMI Handbook, for kindly letting me
use a few of his examples.
• Note: This PowerPoint slide deck is abbreviated version of the slides that were presented on Sept 14,
2017. The original presentation contained some propriety images which were on loan under a “present
only” arrangement with the original authors. Thank you for your understanding.
CONTINUOUS WORK PROCESSES

MOC Audit Validation
ENTRY ENTRY
New System New Display

Major Changes Display Changes
SYSTEM DESIGN IMPLEMENT OPERATE Continuous
STANDARDS Improvement
Console Design Build Displays In Service
Philosophy
HMI System Build Console Maintain
Style Guide Design
Test Decommission
Toolkits User, Task,

Functional Train
Requirements
Commission
Continuous Display Design
Verification
Improvement
Using ISA-101 & High Performance HMIs – summary slides Source: ANSI/ISA-101.01-2015, Human Machine Interfaces for Process Automation Systems
Outline
• Why Do We Care About the HMI?

• Operator Effectiveness for Normal Operations and
Abnormal Situation Management
• The History of HMIs in Industry
• Examples Common Problems with HMI Screens
• Justifying the development of High Performance HMIs
• High Performance Graphic Principles and Elements
• High Performance HMI Display Hierarchy & Navigation
• How to apply ISA-101 and High Performance HMIs
• Summary and Questions

Operator Effectiveness:
Operations Effectiveness:
• Effective controls, systems, tools, and training to enable operators
to effectively detect and successfully handle BOTH normal
operations AND abnormal situations.
• The Three Components
• Effective Alarm Management
• Control System Performance
• High Performance HMI Alarm
• Effective Operations Requires System
all three aspects
• Effective Abnormal Situation
Management also requires all three
• The Alarm System is an essential Circle
but small part of the overall HMI! Represents
• Operator vigilance involves the HMI
ENTIRE HMI – not just the alarm system! Experience
Overall
Operator
Using ISA-101 & High Performance HMIs – summary slides HMI
5
HMIs Past and Present
• Remember the “old days”?
• Provided the “Big Picture”
• Limited Capability
• Many Process Trends
• Status “at-a-glance”
• (but took years to learn)

6
SCADA Graphics Introduced…but no guidelines!
Poor Graphics Encourage Poor Operating Practices

7
Common, Ineffective HMI Depictions
• Common, but
ineffective process
depictions!
• Numbers sprinkled
on a screen
• Inconsistent,
improper use of color
• No trends, no condition information

• Are these processes running well?
8
But the graphics got better over time…
• “Improved” Graphic Capability doesn’t seem to make it any better
• At a glance, what can you tell from this screen?
• What is • Is the process running well? • Is anything

running? abnormal?
WEAO Intelligent Wastewater Systems Seminar – Sept 14, 2017 • What if your are colour blind? 9
One of my favourites…
• So glad this is not from our industry!

10
How do we make better HMIs?
We need to look at what other industries are doing!
Look at industries where the cost of human error is so high that they
have spent the time and energy to develop more effective HMIs
• Oil Refining Industry

• Offshore Platforms
• Power Plants
• Chemical Industry
• Railways
• Aviation
• Mining
• Pulp and Paper
• In 2003 a group of end-users from the process industries got together

and started working on the ISA-101 HMI Design Standard…. they
published it in 2015! ….. It took them 12 years ….

11
2015 Texas City Oil Refinery Disaster from www.csb.gov
• Just a P&ID - no overview, trends, condition information, or material balance
• Inconsistent colors and alarms. 15 killed, 180 injured, $1.5 billion damage
Cited: Poor HMI was significant contributing factor to the fatal accident
Operators could not tell from the HMI that they were continuing to feed fuel into the fire!
12
Situation Awareness in Aviation
Speed Time Enroute Fuel Remaining Positions of Engine Comm & Nav
Altitude Time to next Proximity to nearby aircraft diagnostics Frequencies
Position Waypoint Ground Real-time Data on Available Instrument
Course Time to Proximity to weather & Services at Approaches
Nearby Destination Rising Terrain lightning Airports Glide Radius
Airports

Example is the Garman GTN-650 small
WEAO Intelligent Wastewater Systems Seminar – Sept 14, 2017 aircraft display system
13
If we designed heads up displays like old HMIs
Does the fighter jet pilot stand a chance?

14
The High Performance HMI
Poor HMIs are cited as contributing factors

to major accidents!
Task With “Traditional” With High Improvement
HMI Performance HMI
concepts
Detecting Abnormal
Situations Before Alarms 10% of the time 48% of the time A 5X increase
Occur
Success Rate in Handling
37% over base
Abnormal Situation 70% 96%
case
Time to Complete
Abnormal Situation Tasks 18.1 min 10.6 min 41% reduction
Study by Nova Chemicals and ASM® Consortium

Nova estimated $800,000 per year savings on 1 ethylene plant
PAS-EPRI Study: Similar Results on a Coal-fired power plant
Using ISA-101 & High Performance HMIs – summary slides Figures and Graphic courtesy of PAS
WEAO Intelligent Wastewater Systems Seminar – Sept 14, 2017 (www.pas.com) 15
High Performance HMI Concepts

16
Proper Use of Color
• Color is an attention-getter
• Using Red or Green to indicate
normal “running” or “not running”
makes problems hard to see
• Use color for the abnormal, not the

normal
• Can you quickly tell where the
problems are on these screens?
If you overuse red or green, it no longer stands out

17
Remember these books?

18
How long did it take to find Waldo?
Friendly
SCADA Guy

19
Common Color Blindness or Deficiency
• Very common, different types
• Color change is not detected well in peripheral vision.
• Color alone should not used to differentiate an important status!
Credit: http://play.google.com/store/apps/details?id=com.givewaygames.colorblind_ads
Credit: http://wearecolorblind.com/wp-content/uploads/general-example-2-types2.jpg
Credit: http://www.personal.psu.edu/afr3/blogs/siowfa12/color_blind_12.jpg
20
A word about Colour Schemes
Better Colour Scheme
Poor Colour Scheme

What parts of the
WEAO Intelligent Wastewater Systems Seminar – Sept 14, 2017 screens catch your eye? 21
You can show a lot of grayscale
In this example,
colour is only used
to show alarms
HAPPY PLANT =
no alarms, no colour

22
Data is Not Information: Is Spot Sick?
Blood Tests for Spot
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

Unless you are vet,
L/M 2.7 x109 /L how can you know?
PLT 310 x109 /L
Example adapted from High Performance Handbook Nice Teeth, eh?

23
How About Now?
You can tell at a glance
Blood Tests for Spot

Test Results Range Indicator
Low - 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
Example adapted from High Performance Handbook

Analog in Industrial Examples
RECYCLE COMPRESSOR K43

Cool Suct Inter Dsch Suct Inter Dsch E. Vib N. Vib W. Vib Motor Oil Oil
gpm psig psig psig degF degF degF mil mil mil Amps psig degF
2 Alarm Indicator
290 Alarm Range
170
38.7 Desirable
93.1 95 120 12 9 Operating
185
8 170 Range
42.7 80
Alarm Range
Interlock
Show Values Show Trends Indicator
Buttons for additional functionality Image from High Performance Handbook

25
Alarm Indications on Graphics
Often 480.1 psi No Alarm Indication 480.1 psi Only a Colour

Seen Change!
480.1 psi 480.1 psi 480.1 psi 480.1 psi

Better Diagnostic Priority 3 Priority 2 Priority 1
Priority
480.1 psi 480.1 psi 480.1 psi 480.1 psi

Betterer Diagnostic Priority 3 Priority 2 Priority 1
Priority
4 3 2 1 S
480.1 psi 480.1 psi 480.1 psi 480.1 psi 480.1 psi
Best!
Diagnostic Priority 3 Priority 2 Priority 1 Suppressed
Priority Alarm
Show alarms in multiple ways: Colour, Shape, Text (“redundant coding”)

Adapted from High Performance Handbook
Embed information into the HMI!
HI
0.75 mg/L
AIT01-HI Chlorine Treatment High Residual Alarm

Alarm: HIGH Setting: 120 deg C Priority: 3
Class: OPERATIONAL Response Time: <15 min
Alarm Consequences: Alarm Causes: Corrective Actions:
High Hypo Usage Hypo Pump Problem Check dosing rate
High Dechlor Usage Pump in Manual Adjust dosing rate. See. SOP
26
Problem with Feed Valve Visit site and inspect pump
Bad load of Hypo Go to site and do manual
hand sample
Problem with Analyzer
Alarm Information Record from the SCADA System’s Master Alarm Database
Using ISA-101 & High Performance HMIs – summary slides – see the ISA18 alarm management standard
The Importance Of Trends
Embedded “always visible”

Very Different Situations only detectable via trends
trends on process displays
are always better.
Don’t’ rely on “trending on

demand”, “trend pop-ups”
or “trend screens” –
in practice they don’t’ work
very well.
Best Practice:
Embed Trends on HMIs
Image from High Performance Handbook

More concepts with Trending
Plant 1 startup
• Would these 80
60
RAS feed rate
graphs 40
help start up 20
65.1
0
your plant? 20
Aeration
15 Level
10
5
21.1
0
8
Residual
6 Chlorine
4
2
6.9
0
+30 +60 +90
Adapted from image courtesy of PAS (www.pas.com)
Keep it simple
Crude To Scrubber
Feed
TK-21
Poor Vessel To Product

and Line Tank
Depiction !
Better Vessel
and Line Not a navigation target
Depiction
SCRUBBER
OPEN CRUDE Navigation target

FEED
TK-21
PROD TANK

Level Depiction

Status Depiction
Red/Green for
status
vs.
Greyscale & STOPPED
redundant
Not
Running
L L
coding
RUNNING
Running A A
Pumps not monitored by SCADA (no status information) are just shown as mid-gray:

Don’t do this

Or this…

Or this..

Proper Hierarchy for Displays
• HIERARCHY for Displays:

• Level 1 – Plant or Entire System Overview
• Entire Operator Span of Control. “Single-Glance”
• Level 2 – Sub-Process Overview
• More details than a Level 1 display, smaller area
• Level 3 – Equipment or Details Screen
• Specific details about part of the process or control
• Level 4 – Specific Task or Diagnostic Screen
• Very detailed screen, only used for diagnostics

36
Level 1 Overview
Run Plan:
Reactor 1 Actual: Hydrog A Key Performance Indicators
Comp A Comp B Cool CPC CRM LVL Prod: Thionite Cycle Bed Bed Conversion Efficiency
State: Mid-Run Comp A
A1 A2
Agit: ON 80
Locks: CLEAR
Suct Dsch %
Balance
IN OUT
500
80.0
F
Rate L
70 12 HR
VIB: OK O
W Emissions Limit Ratio
72.0 BRG: OK
2 HR OIL: OK 470 1.0
Locks: CLEAR 2 HR
Run Plan:
Reactor 2 Actual:
Hydrog B
2 Bed Bed
Comp A Comp B Cool CPC CRM LVL Prod: CRM-114 Cycle
B1 B2
State: Mid-Run Comp B 12 HR
Agit: ON 0.5
Locks: CLEAR Suct Dsch
Balance Feed System Aux Systems
IN OUT 500
Feed A Feed B Feed C SynG CWT CWP S10 S200
68.0
F
Rate L
VIB: OK O
BRG: OK W
60.0
2 HR OIL: OK 470 Atv 1 Atv 2 Pres %IP PWR VentP VentT MGA
Locks: CLEAR 2 HR
Alarms: P1 P2 P3 P4 Toggle
ACK 0 1 2 4 Main Reactor Reactor Hydrog Hydrog
List /Summary
UNACK 0 0 1 1 Menu 1 2 A B
2 071608 08:55:07 RX2 LOW CRM –QUALITY EXC
Clr T-In T-Out Visc C57D Null-A Jup2 Grok
Trend Feed Aux Menus

Control Sys Sys L2 L3 L4

37
Level 2: Control of a Process Sub-Part
Feed Components: A - B - C VENT SYS Product: Thionite State: Mid-Run
Agitator
ON Material Balance
Main Feed
P 76.8 MPH
Reactor M5 M5 Pressure
P 98.0 psig
S 76.0 S 95.0 SHUT Reset
Analysis: Purity %
O 88.5 % 40.0 O 44.3 % DOWN
AUTO AUTO M5 IN OUT
Main Feed MPH +10%
80.0
+/- 5 psi, 2hr
FREEZE
32.0
-90 -60 -30 2 Hours +/- 1 %, 2hr M5
Analysis: Inhibitor Concentration %

6.0 -10%
72.0
-90 -60 -30 2 Hours
M5 Level % 19707 19301
Additive 1 P 71.0 % ISOLATE
S 70.0 Calc Diff: 2.1 %
P 11.9 MPH O 54.3 %
M5 Hours: 238.1
S 12.0
O 22.3 % AUTO Since: 06/02/07
AUTO 14:00:00
4.0
-90 -60 -30 2 Hours
Additive 1 MPH 5.0 % Run Plan:
14.0
Actual:
92.0 MPH
PRODUCT
52.3 %
10.0 Hours
-90 -60 -30 2 Pumps Pump 1 Diagnostics Pump 2
Additive 2 Needed 1 RUNNING 1-OK 2-BAD STOPPED
P 4.0 MPH 4
S 4.0
O 44.3 %
AUTO To Coils M5 Temp Temperature °C
P 45.0 °C 48.0
Additive 2 MPH S 45.0
6.0
O 54.3 %
AUTO
Coolant Purge Cat.

Flow Rate Activity
40.0
Coolant Conversion Reserve COOLING SYS -90 -60 -30 2 Hours
2.0 Temp Efficiency Capacity
-90 -60 -30 2 Hours
Level 1 M5 M5 - Level 3 - - Level 3 -

Main Trend Feed Product
Reaction M4 M6 Startup Sequence M5 M5 Cooling
Menu Control System Recovery
Overview Overlay Overlay Interlocks System

38
Level 3
Most of OH
20.1 psi
EAST COMP West Compressor
what you WEST WC Speed

P 90.8 %
IDLE PURGE
SHUT
COMP S 90.0 DOWN
already RUNNING
O
CAS
90.0 %
90.8
90.0 32.0
111.0
WEST
COMP
WEST
COMP
WEST
COMP
48.0 65.0
have is 111.0 °C
probably 48.0 psi

West Compressor Interlock W-1
Initiator Value Action Status
65.0 °C Speed 1 Stg 2 Stg CLR CLR Winding
Level 3 1st
Stage 20.0 °C
psi psi In Out Temp Overspeed
Or Winding Temp High
OK
OK
Shut Down
West Comp
AND
CW SHOW / HIDE NORMALIZE Or Vibration High OK Close Inlet &
VALUES SCALE
28.0 °C Or 1 Stg High Pres Outlet Block
44.0 °C 2nd OK
Valves
Stage 32.0 °C Flow Demand SPEED Or 2 Stg High Press OK AND
We are EAST COMP
P 76.8 MSCFH
S 76.0
O 88.5 %
CASCADE
IN EFFECT
Or Suction Pres Low OK Override East
AUTO Comp Speed
out of 90.0 psi 48.4 MSCFH
RECOVERY
Or Oil Pres Low OK
to 100%
time! West Comp Discharge Temp °C West Comp Flow MSCFH West Comp Speed %
50.0 55.0 95.0
40.0 45.0 85.0

-90 -60 -30 2 Hours -90 -60 -30 2 Hours -90 -60 -30 2 Hours
West West Comp

Main Compression East Trend OH Product - Level 4 -
Startup Sequence Cooling
Menu Level 2 Comp Control System Recovery Procedures
Overlay Overlay System

Back to Level 1 –
How many values/indicators are on this screen?
Run Plan:
Reactor 1 Actual: Hydrog A Key Performance Indicators
Comp A Comp B Cool CPC CRM LVL Prod: Thionite Cycle Bed Bed Conversion Efficiency
State: Mid-Run Comp A
A1 A2
Agit: ON 80
Locks: CLEAR
Suct Dsch %
Balance
IN OUT
500
80.0
F
Rate L
70 12 HR
VIB: OK O
W Emissions Limit Ratio
72.0 BRG: OK
2 HR OIL: OK 470 1.0
Locks: CLEAR 2 HR
Run Plan:
Reactor 2 Actual:
Hydrog B
2 Bed Bed
Comp A Comp B Cool CPC CRM LVL Prod: CRM-114 Cycle
B1 B2
State: Mid-Run Comp B 12 HR
Agit: ON 0.5
Locks: CLEAR Suct Dsch
Balance Feed System Aux Systems
IN OUT 500
Feed A Feed B Feed C SynG CWT CWP S10 S200
68.0
F
Rate L
VIB: OK O
BRG: OK W
60.0
2 HR OIL: OK 470 Atv 1 Atv 2 Pres %IP PWR VentP VentT MGA
Locks: CLEAR 2 HR
Alarms: P1 P2 P3 P4 Toggle
ACK 0 1 2 4 Main Reactor Reactor Hydrog Hydrog
List /Summary
UNACK 0 0 1 1 Menu 1 2 A B
2 071608 08:55:07 RX2 LOW CRM –QUALITY EXC
Clr T-In T-Out Visc C57D Null-A Jup2 Grok
Trend Feed Aux Menus

Control Sys Sys L2 L3 L4

40
How to show a piping system
Show:
• Topology, not Geography
• Important Status Conditions and Alarms
• Significant highway, railway and river crossing
• Residential areas near pipelines
• Important boundaries (i.e. state lines)
• Moving Analog Indicators indicating performance.
• Direction and content indicators
• Key process values
• Important trends
• Other ideas???

41
Pipeline Overview Screen
You could show it this way….

R77
N28
Farnam 6
Adams 3
Marcum
C16
CSX9
Tempe
Source: PAS Internal Adaptation

42
This is probably a lot easier to use
Image courtesy of PAS (www.pas.com)

43
High Performance HMIs
How do we design and manage our HMI in order to

use these concepts?
Introducing the ISA-101 HMI Design Standard

ENTRY ENTRY

Philosophy
Style Guide Design
Test Decommission

Functional Train
Requirements
Commission
Verification
Improvement
HMI Lifecycle from ANSI/ISA-101-2015

44
ISA-101 – in a nutshell
Actual ISA-101 standard is only 64 pages
Overall design guidance provided in the actual standard, details

are in ISA-101 Technical Reports (soon to be available from ISA)
Has a very robust workflow for developing and managing HMI

systems, including a strong Change Management Process
Focus is on creating screens for situational awareness and

operator tasks. Users must be trained on use to use HMIs.
Facility owners must develop a clear HMI philosophy document

and HMI style guide for their HMI system, and couple this
reusable software toolkits of screen elements. Without these it
is impossible to develop an effective HMI.

Take another look at the workflow
The ISA-101 standard is important because it is the

first international standard to state minimum
requirements for HMI displays, including their design,
documentation, and management of change.
ENTRY ENTRY

Philosophy
Style Guide Design
Test Decommission

Functional Train
Requirements
Commission
Verification
Improvement

46
How to get started?
Understand and document what you have

Add some Level 1 and Level 2 displays to give your operators visibility
of your entire process for situational awareness
Add some task screens to help with start-up, shutdown or
maintenance tasks that are difficult for operators to run
Start developing your HMI Philosophy document and Style Guide to
define what you want your system
Start using Revision Control to track changes to your SCADA system’s
programming. Implement a Management of Change procedure, so
changes are controlled and documented.
Do a pilot project of a few new HMI screens to see how they work.
Talk to your operations team.

47
Any Questions?

* Not a High Performance HMI
48

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Using ISA-101 &

High Performance HMIs for

Speaker: Graham Nasby

• Water SCADA & Security Specialist

• 10 years in the consulting sector, followed by 2 years at the city

• WEAO and OWWA Member, Member of OWWA Automation Committee

• Has published over 30 papers and articles on automation topics

Using ISA-101 & High Performance HMIs – summary slides

CONTINUOUS WORK PROCESSES

New System New Display

Toolkits User, Task,

• Why Do We Care About the HMI?

Using ISA-101 & High Performance HMIs – summary slides

Using ISA-101 & High Performance HMIs – summary slides

Poor Graphics Encourage Poor Operating Practices

• No trends, no condition information

• What is • Is the process running well? • Is anything

Using ISA-101 & High Performance HMIs – summary slides

• Oil Refining Industry

• In 2003 a group of end-users from the process industries got together

Using ISA-101 & High Performance HMIs – summary slides

Using ISA-101 & High Performance HMIs – summary slides

Does the fighter jet pilot stand a chance?

Poor HMIs are cited as contributing factors

Study by Nova Chemicals and ASM® Consortium

Using ISA-101 & High Performance HMIs – summary slides

• Use color for the abnormal, not the

If you overuse red or green, it no longer stands out

Using ISA-101 & High Performance HMIs – summary slides

Using ISA-101 & High Performance HMIs – summary slides

Using ISA-101 & High Performance HMIs – summary slides

Better Colour Scheme

Poor Colour Scheme

Using ISA-101 & High Performance HMIs – summary slides

Using ISA-101 & High Performance HMIs – summary slides

Blood Tests for Spot

HGB 10.2 g/dl

MCHC 32.2 6/dl

WBC 9.2 x109 /L

GRANS 6.5 x109 /L

PLT 310 x109 /L

Example adapted from High Performance Handbook Nice Teeth, eh?

Blood Tests for Spot

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

Example adapted from High Performance Handbook

Using ISA-101 & High Performance HMIs – summary slides

RECYCLE COMPRESSOR K43

290 Alarm Range

Buttons for additional functionality Image from High Performance Handbook

Using ISA-101 & High Performance HMIs – summary slides

Often 480.1 psi No Alarm Indication 480.1 psi Only a Colour

480.1 psi 480.1 psi 480.1 psi 480.1 psi

480.1 psi 480.1 psi 480.1 psi 480.1 psi