OPERATOR INTERFACES

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• Require well engineered human interface
system for error free interaction
• Instrumentation and control engineers:
setting up and maintaining control system
• Plant operator : monitoring, supervising and
running the process during startup, operation
and shutdown condition

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• Low level human interface : to local control
unit (LCU) or data input output unit (DI/DO)
via dedicated line
• High level human interface : to LCU or DI/DO
via shared communication facility

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ADVANTAGES
Reduction in control room size (no panel board instrumentation)
Reduction in wiring cost (LCU near process)

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• Interface equipment must be designed to
meet
– Large as well as small systems
– Centralized and distributed equipment
configuration
– CRT only operation or panelboard instrumentation

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 Requirements
1. Process monitoring
– Current values of all process variables in system
– Identified by tag rather than address (descriptor
for that tag associated)
– Display of PV in engineering units with values
– Variables (functions of basic PV) available all
time in format

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• Alarming
– Alarm status identified by control and computing devices
for each variable in DCS reported in clear manner
– Also for computed variables
– Display alarm along with PV or accessible to the operator
– Alert and acknowledge from the operator
– Multiple alarm in short time, informed with priority
– Multivariable alarm (abnormal depend on several
variables) – appropriate mechanism to report the same
Trend in time
Fast access to recent history of selected PV known as
trended variable(TV)
Requirements in trending
• group related TV
• Trend graph in engineering units
• Able to obtain precise recent and trend variable
• Also show auxiliary information; to evaluate status
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2. Process control
o Rapid access to all continuous and logic sequences
o Continuous control loop: changing control modes, set
points and monitor results
o Logic: starting and stopping pumps, opening and closing
of valves
o Batch process: observe current status, and interact to
initiate new steps or halt sequence
o Both cases: access to and be able to manipulate (if any
single point failure)

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3. Process diagnostics
Abnormal conditions caused by equipment or I&C
system, identify, correct
•Ongoing tests and reasonable checks on sensors
•Ongoing self-tests on components and module
Automatic diagnostics functions
1.First-out alarming function
2.Priority alarming functions
3.Advanced diagnostic function (failed process equipment and
mode of failure)

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4. Process record keeping
Periodically note and record the current values
Record keeping requirements
1. Recording of short-term trending information
2. Manual input of process data
3. Recording of alarms(with tag name, time, return to normal,
operator acknowledgement)
4. Periodic records of process variable information
5. Long-term storage and retrieval of information
6. Recording of operator control actions

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5. Guidelines for human factors design
– Convenience of equipment vendor or architect-engineer
– Later operator - Fewer operator errors
» Less operator fatigue
» Efficient use of personnel
Guidelines
1.Full range of expected operator population (male, female, large, small)
2.Minor disabilities (color blindness, near sightedness)
3.For operators not computer programmers
4.Rapid access to all necessary controls and displays
5.Arrange (equipment, displays) based on operational point of view, cluster
6.Use colors, symbols, labels to minimize operator confusion
7.Do not flood parallel information, give prioritized, arranged and
meaningful
8.Aid with operator guides, menus, prompts or interactive sequences
9.Detect and filter erroneous operator input, tell operator what to do next
10.Control room equipment is consistent with proper selection and design of
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 low-level Operator Interface
Motivations to use LLOI
• Provides interface that is familiar to trained operator
(resemble type of instrumentation)
• Less expensive than HLOI
• It can provide manual backup incase automatic or HLOI
fails
LLOI includes
– Control stations, indicator station, alarm annunciators and trend
recorders

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Control station - continuous

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Control station -logic

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 High level operator interface
• LLOI uses panel board instrumentation
• HLOI uses CRT, video display units
• Uses keyboard instead of switches
Microprocessor based digital technology
Advantages
1. Control space reduced significantly
2. Flexible (no panel board instrumentation)
3. Microprocessor cost effective implementation of functions
Consists of
Operator displays, keyboard or input devices, main processor and
memory, interface to shared facility and hard copy devices
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Disadvantages
•All in one basket, vulnerable to single point failure
•Single-processor, single-memory-less loops, datas
•Not scalable, expensive for small systems
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First available standard

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OPERATOR DISPLAYS

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Big picture of current plant condition
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Situation in a selected plant area
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Alarm and operational status of process variables in the plant,
but to control, require display similar to panel board instrumentation
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Group graphics display Includes piping and instrumentation diagram
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Single loop or data points for control and analysis purpose

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Use to both operator and instrumentation engineer

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• Design consideration for displays
– Not cluttered, simple as simple
– Not flashy and proper background for display
– Top few lines display common information
– Proper color conventions of industry
– For color blind use underline or blinking

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• Design consideration for operator input
– Display-select commands
– Cursor-movement commands
– Control-input commands
– Data inputs

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Engineering interface

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• Human interface - to monitor and control
• Engineer – to put DCS onto field
– Design for engineer to monitor, control, procure,
arrange, wiring, testing
– Select device for operator, mount in panelboard,
wire, test
– documentation
– Error detected – new module, wiring,
documentation update

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• Dedicated inter module wiring replaced by shared
communication
• CRT based instead of huge panel board
Engineering made simple
Special hardware (part of DCS) to make this painless –
Engineering interface

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• Low-level engineer interface
– Min. function devices
– Inexpensive
– Small
• High-level engineer interface
– Full function devices
– Powerful (expensive)
– Medium and large

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Functions
• System configuration
– Define H/W configuration, interconnection, algorithms
• Operator interface configuration
– Define equipment, relate this to DCS
• System documentation
– System and interface for quick changes
• System failure diagnostics
– Determine existence of failure, quick and efficient

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Requirements
• Access security:
– control logic and tuning parameter, unauthorized not allowed
• Ergonomic design:
– not for programmers,
– many devices- interface between them
• Data reasonable and consistency:
– check with previous entered value, prompt to correct,
– enter not more than once,
– many control for one- pick, keep track,
– for several related H/W, system should provide check
• User convenience
– Easy storage when not in use
– No need to shut down to connect or disconnect devices (convenient)
• Cost effectiveness
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 System configuration requirement
• Manual work
– determining control system requirement
– Selecting and procuring H/W
– Physically assembling
– Connecting wires between transmitter and terminating point in
control room
1. Define address of I/P, O/P points in system
2. Define tag name and descriptor, relate these to tags
3. Signal conditioning (if required) of I/P
• Linearization, zero or span shifting, conversion (O/P too)
4. Select, configure and tune control and computational algorithm
• Define auxiliary function- trending, logging
5. Requires transmission, define link from element to other
• System to check, so preloaded, duplicate in mass storage
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 Operator interface configuration
requirement
• Implement panel board or video display unit
Functions
• To select and define devices and mechanism
for operator
– Control station, indicators, recorders
• Relate operator interface or display to control
&instrumentation H/W in field
– Labelling devices, display with tag

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 Documentation requirement
• Bulk of configuration through engineering
interface and stores in mass storage
– Include hard copy to support documentation
– Support tabular and graphical data format
– Keep track of field changes
• EI must handle these changes, as well as original design
– Automatic with less human effort

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Diagnostics of system requirement
• Self diagnostics (intelligent individual device)
• Identify failed devices
– Sensors, power supply, communication devices
• Partial failure
– Severity and nature, to identify
• Trouble shooting of control system
– Initial, online
– Continuous, logic, batch

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 Low-level engineering interface
• Micro-processor based
• Can be
– hand held
– module that can be mounted
• Minimal input, output
• Plug and play-not needed throughout
• Use of code word, symbol – min I/O,O/P

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System configuration
• H/W selected and configured manually
• Provide with guides or documentation
• LLEI to provide tool for configure algorithm
– Enter control strategies, setting tuning parameters, alarm
limits, etc
• Storage available, W/O controller, only with power
supply and controller limits
– Upload from controller, or download to controller
• Not support high-level language

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Operator Interface Configuration
• Minimum devices – manually
– Assign tag names, labeling station
• Difficult, time consuming, prone to error
Documentation
• Manual – with standard forms
Diagnosis Of System Problems
• Not always connected
• Rely on Self test of equipment

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 High-level Engineering Interface

• Cost-effective for medium and large system

• CRT console or VDU
• Similar to HLOI
• Modular- keyboard, printer added- flexibility
• Same elements of Operator interface used for
Engineer interface
• Interact through Communication facility

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Dual – console function
• Operator- display, mode selection, control operation
• Engineer- control logic configuration, modification,
tuning, documentation

• Engineering interface not required always

– Using switch can be changed to OI or EI
– Cost effective
– Switch also provides security for EI

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Special hardware required
• Operator interface- not much input/output, so simple
keyboard
• Engineer interface- wider range of input, use of
general purpose keyboard
– Special characters- special purpose
– Printers or plotters for documentation

Portable Engineering interface

• Compromise between full function and minimum
function
• Bulk memory, plug and play type, for single LCU or
cabinet
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System configuration
• HLEI – major role in automating process
• Control structures, computational algorithm stored in HLEI. Following
information
– Number, type and location of H/W in LCU
– Definition of any H/W selected on each module
– Define input point to H/W module
– Number, type and location of all operator and engineering consoles in the
system
– Number, type and location of any other device that communicate using
shared communication facility(special logging or computing device)
• Some manually others automatic using broadcast messages
Control and computational information
 Tags, descriptors, definitions, addresses
 Logic state descriptors for digital system
 Signal conditioning in DI/OUs
 Communication linkages
 High-level language computation algorithms
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• Control and computational logic configuration
– Fill-in-the-blanks function; through sequence of prompts and
responses
– Graphics capability engineer draws using light pen, similar to
CAD
– Enter debug and check high level language routines

• Storage of configuration
– Use of mass memory to store configuration information
• Control logics without presence of target H/W
• Verify engineer input to LCU; comparison from mass storage
• Failed devices replaced with new one, configuration
downloaded to it
• Upload configuration from device to interface
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Operator interface configuration
• Configure or change display structures
– Number of areas in plant, identifying tags and descriptors
– Number of groups in each area
– Assignment of control loops and input points to group
– Types of display at each level (preformatted or custom)
– Linkages between displays
– Assignment of points in system for special function
• Layout of display
– Graphic symbols
– Static background elements
– Dynamic graphics elements
– Dynamic alphanumeric elements
– Control stations
– Poke points- touch screen

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• Operator input mechanisms
– Special function definition
– Graphics drawing and editing
– Symbol modifications
– Macro symbol operations
– Display transportability
– Expanded display definition

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Documentation
• Following documentation automatically
– List of H/W modules and their location
– Control configuration and associated tuning parameters for
each LCU
– Listing of tags, descriptors, H/W address of I/P or O/P
modules
– Listing of special operator interface function with tag
– Operator display in system with drawing and display
hierarchy

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Diagnosis of system problems
• Most of H/W devices is microprocessor based,
intelligent to perform on-line self-diagnosis

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