WWAC2015 Situational Awareness - Krajewski.ppt · IGNITOR HEADER PERMISSIVES SATISFIED ... Feed Sys Aux Sys Reactor 1 L2 Trend Control ... Wonderware Situational Awareness Symbol

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Situational Awareness

The Next Leap in Industrial HumanMachine Interface Design

2015 ISA Water / Wastewater and Automatic Controls SymposiumAugust 4-6, 2015 – Orlando, Florida, USA

Speakers:John Krajewski

2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA 2

Presenter – John Krajewski

• John has 20+ years of experience in industrialautomation and control systems.

• John began his career working as a Control SystemEngineer in the potable water industry.

• Subsequently, John worked as an Application Engineerfor a System Integrator who primarily focuses on thepharmaceutical and biotech industries.

• He joined Wonderware Inc. in April 2000 as a SeniorApplication Developer in the Product MarketingDepartment.

2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA

IncreasedSize and

Complexity

IncreasedData

Volumes

RemoteOperations

IncreasedLevels of

Automation

Staffing/Education

Challenges

Trends in Industrial Automation


1970’s 1980’s 2000’sFUTU

RE

HMI Evolution/Current State


Althoughpleasant to see,

much of thisgraphic is

irrelevant to thecontrol.

Key Principles –Distracting and Irrelevant Detail


• Although pleasant tosee, much of this

graphic is irrelevant tocontrol the process.

• These are the onlyobjects providinginformation to the

operator:

Key Principles –Distracting and Irrelevant Detail


The average percentages shown had the following:•People and work Context Factors: 35% - 58%•Equipment Factors: 30% - 45%•Process Factors: 3% - 35%

Abnormal SituationA disturbance or seriesof disturbances in aprocess that causeplant operations todeviate from theirnormal operating state.

Source: ASM Consortium

Impact of Human Error


Situational Awareness

The perception ofenvironmentalelements with respectto time and/or space,the comprehension oftheir meaning, and theprojection of theirstatus.


Creating the Business Case


• Poorly performing alarm systems ANDHMIs are contributing factors to majoraccidents and poor operatingperformance.

• Proper Alarm System Management andAlarm System Performance is essentialto maximum-efficiency operations.

• There are multiple contributing factors:

AlarmManagement

Human MachineInterface

ControlLoop

Performance

Safe and Reliable Control


Measurable Costs/Value

Raw Materials Process Products/Services

En

erg

yW

as

te

$

$

$

$

Business Value = Products(Availability) – Energy – Raw – Waste


Goal Oriented Design

• Common Mistake – The System is the Goal.

GoalDirectedTaskAnalysis


Display structure

Level 1 – Area-wide overviews– KPIs, summary status information

Level 2 – Facility-wide overviews– key operating screens, specialty pages

Level 3 – Detailed operating information– similar to most current screens

Level 4 – Auxiliary information– help screens, trend pages, etc.


Reduced Navigation

Start-up/Shut Down Info

NO MASTER FUEL TRIPPURGE COMPLETEFUEL GAS ONABC RESETABC MODE MANUALIGNITOR HEADER PERMISSIVES SATISFIEDGAS HEADER PERMISSIVES SATISFIED

STM F BFW F

DL

BP

FD (P)

% O2

STMT

Air F

IGN

B2IGMN

BURNER STARTREGISTER OPENMODE AUTOIGNITOR ONIMPELLER OUTOIL BURNER ONSAB ON

N W COO2

BTU/C

900#

TN-BN

TS-BS

TS-BN TN-BS

BFW

Boiler Metal Temperatures

FG

202 Boiler Start-up

% MCR

100

0

BM %

100

0

LB %

50

0

202

-50

Pre

ssu

re(P

SIG

)Time (min)

10 20 30 SAT Steam0

100

200

300

400

500

600

700

800

900

1000

Sat Steam ROC(oC/hr)

Last hr: 0.00Current: 0.00

SH Steam ROC(oC/hr)

Target: 0.00Current: 2.00

To 100oC DrumBottom Temp (oC)

Target: 0.00Current: 2.00Last hr: 0.01

Drum Press ROC(psig/min)

Last hr: 0.20Current: 0.00

Task Orientated Level Two Displays

-To startup operator had to visit 12 screens.

-Operational level 1 screen to start up a Boiler


Color and Attention

Source: NASA Ames Research Center Color Usage Lab

http://colorusage.arc.nasa.gov/popout.php

Color is a powerful way to guideattention

– Your eye is automatically drawn tocolored objects

• This is called the “pop out” effect

– Now try this one…

Color is a powerful way to guideattention

– Your eye is automatically drawn tocolored objects

• This is called the “pop out” effect

– Find the the “L”s and “I”s

in this picture…


• Situational Awarenessfocused displays takeadvantage of the “popout” effect to guideoperators’ attention tovalues that are inalarm

Click andwatch forthe alarm…

Color and Attention


Color and Attention

Source: NASA Ames Research Center Color Usage Lab

http://colorusage.arc.nasa.gov/popout.php

The Effectiveness of the Pop Out Effectdrops dramatically as additional colorsare added.

– Lets add just 3 more colors and seethe impact…


Different tastes…

Reactor 1

ThioniteMid-RunONCLEAR

Prod:State:Agit:Locks:

Run Plan:Actual:

IN OUTBalance

Menus

MainMenu

FeedSys

AuxSys

Reactor1

L2

TrendControl

Comp A Comp B

72.0

80.0

2 HR

Cool CPC CRM

Rate

Reactor 2

CRM-114Mid-RunONCLEAR


Run Plan:Actual:

Balance

Comp A Comp B

60.0

68.0

2 HR

Cool CPC CRM

Rate

IN OUT

Hydrog A

BedA1

BedA2

Suct Dsch

OKOKOKCLEAR

VIB:BRG:OIL:Locks:

CycleComp A

470

500

FLOW

2 HR

Hydrog B

BedB1

BedB2

Suct Dsch

OKOKOKCLEAR

VIB:BRG:OIL:Locks:

CycleComp B

470

500

FLOW

2 HR

Alarms:ACKUNACK

ToggleList /Summary

P100

P210

P321

P441

Reactor2

HydrogA

HydrogB

L3 L4

70

80

%

12 HR

Key Performance Indicators

Conversion Efficiency

0.5

1.0

12 HR

Emissions Limit Ratio

Feed A Feed B Feed C SynG

Feed System Aux Systems

Atv 1 Atv 2 Pres %IP

Clr T-In T-Out Visc

CWT CWP S10

PWR VentP VentT

C57D Null-A Jup2

S200

MGA

Grok2

2

071608 08:55:07 RX2 LOW CRM –QUALITY EXC

LVL

LVL

Reactor 1

ThioniteMid-RunONCLEAR


Run Plan:Actual:

IN OUTBalance

Menus

MainMenu

FeedSys

AuxSys

Reactor1

L2

TrendControl

Comp A Comp B

72.0

80.0

2 HR

Cool CPC CRM

Rate

Reactor 2

CRM-114Mid-RunONCLEAR


Run Plan:Actual:

Balance

Comp A Comp B

60.0

68.0

2 HR

Cool CPC CRM

Rate

IN OUT

Hydrog A

BedA1

BedA2

Suct Dsch

OKOKOKCLEAR

VIB:BRG:OIL:Locks:

CycleComp A

470

500

FLOW

2 HR

Hydrog B

BedB1

BedB2

Suct Dsch

OKOKOKCLEAR

VIB:BRG:OIL:Locks:

CycleComp B

470

500

FLOW

2 HR

Alarms:ACKUNACK

ToggleList /Summary

P100

P210

P321

P441

Reactor2

HydrogA

HydrogB

L3 L4

70

80

%

12 HR

Key Performance Indicators

Conversion Efficiency

0.5

1.0

12 HR

Emissions Limit Ratio

Feed A Feed B Feed C SynG

Feed System Aux Systems

Atv 1 Atv 2 Pres %IP

Clr T-In T-Out Visc

CWT CWP S10

PWR VentP VentT

C57D Null-A Jup2

S200

MGA

Grok2

2

071608 08:55:07 RX2 LOW CRM –QUALITY EXC

LVL

LVL


Flexible Style Libraries


Severity 1 response time < 5min

2

4

3




1

Best Practices: Alarm signalingin the HMI displays


Navigation Badges

Reactor 31

1 2 1 3

Reactor 323

Reactor 33

2

Overview

1 4 1 6


Equipment Meters/Polar Stars Dashboard Tools

• Agitator/Settler

• EquipmentStatus

• Feeder

• Hand SwitchSelector

• HeatExchanger/Fan

• Loop Block

• MiscellaneousEquipment

• Multistage Pump

• Numeric Data

Block

• Output Bar

• Parallel ControlValve

• Pump/Blower/Rotary Valve

• RotatingEquipment

• Sequence Button

• Tank/Vessel

• Thickener

• Valve/Damper

• Invisible ProfileMeter

• KPI Bar

• Meters

• Multi-LevelMeter

• Rake HeightMeter

• RPM Meter

• MeterConnector

• Small FlowTracker

• Polar Star 3Spoke

• Polar Start 4Spoke Diamond

• Polar Start 4Spoke Square



• Bar Chart

• Box Chart

• Bullet Graph

• Column Chart

• Column ChartPairs

• Column ChartTrips

• Deviation Chart

• ParallelCoordinatesChart

• Pie Chart

• StackedColumn Chart

• StackedColumn ChartAlarms

• Target Graph

• ValueComparisonChart

• VariableMonitoring Bars

• Win Loss Chart

Wonderware Situational AwarenessSymbol Library


Information comes from putting data in context– When data is presented without context it forces operators

to remember or search for the related values

Data withoutcontext

How far is it fromsetpoint?

Is it getting close toalarming?

Is it inside thenormal operatingrange?

At best, this isinconvenient – butduring an upset it canlead to slower responsetimes and cause costlyerrors

Data vs Information


Data vs Information


m3/h

FIC 123

C

Meter Components

PV in ideal range

PV near edge ofideal range –watch moreclosely

PV outside ofideal range –considertaking action

Glance Test

When you click, an example will appearbriefly at the far right of the screen –see if you can tell whether the PV isinside the optimal range or not

Each examplewas only shownfor ½ of a second


Multivariate Analysis


Multivariate Analysis


Putting it all together…


Benefits…

Task With TraditionalHMI

With HighPerformance HMI

Result

Detecting AbnormalSituations beforealarms occur

10% of the time 48% of the time A 5X increase

Success rate inhandling abnormalSituation

70% 96% 37% over basecase

Time to completeabnormal situationtasks

18.1 min 10.6 min 41% reduction


How do you eat an elephant?

One bite at a time…


Past Future

Process Parameters Situational Awareness

Labor Resources Information Craftsmen

Reactive Operations Proactive Operations

Operating a ProcessReal Time Business

Management

Evolving Industrial Operations


Documents

WWAC2015 Situational Awareness - Krajewski.ppt · IGNITOR HEADER PERMISSIVES SATISFIED ... Feed Sys Aux Sys Reactor 1 L2 Trend Control ... Wonderware Situational Awareness Symbol