2013 Honeywell Users Group Americas. Jeff England & Dal Vernon Reising Successes & Challenges for Designing Effective Level 1 and Level 2 Displays
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1 2013 Honeywell Users Group Americas Jeff England & Dal Vernon Reising Successes & Challenges for Designing Effective Level 1 and Level 2 Displays 1
2 Presenter Jeff England Corporate Controls Technologist Marathon Petroleum Company LP More than 27 years experience in Process Automation and Refinery Operations 2
3 Co-Author Dr. Dal Vernon Reising Senior partner, Human Centered Solutions LLC North American human factors consulting group Specializes in human performance in process industry operations Former Principal Investigator of Honeywell s Abnormal Situation Management (ASM ) Consortium Human Centered Solutions Helping People Perform 3
4 Presenter Dr. Peter Bullemer, on behalf of Dal Vernon Reising Senior partner, Human Centered Solutions LLC North American human factors consulting group Specializes in human performance in process industry operations Former Director & Principal Investigator of Honeywell s Abnormal Situation Management (ASM ) Consortium Human Centered Solutions Helping People Perform 4
5 Contributors Bryant Price, Andrea Engler Controls Engineers, Marathon Petroleum, Detroit Refinery Charles Bloom, Rich McLain Senior Partners, Human Centered Solutions (HCS) Daniel Chanis Honeywell (Houston), Americas HMI ASM Discipline Leader Strezimir Dukovski, Marin Ruskov, Vladimir Kasabov Honeywell (Bulgaria), HMIWeb Solution Pack Designer Engineers Roman Giraudo Honeywell (Houston), Project Engineer 5
6 Designing Effective L1 & L2 Displays Custom Shape Library Display Hierarchy Design Process Control Displays (L2) for key Chunks of Operation Scope Of Control Overview Display Canvas (L1) Lessons Learned 6
7 Custom Display Library Key Drivers for developing Custom Library Desire to enable direct data entry interaction (No Face Plates) Alarm Icon Presentation customization for dual coding and color salience control Correspondence Coding for Associated Control Strategy Elements Migration readiness support long term 7 Hope for shared improvements in Base Solution Pack
8 Custom Display Library - Direct Data Entry Set Point Controller Modes Output Custom Keypad 8
9 Custom Display Library - Direct Data Entry Discrete Select Menu Menu appears on Click Confirmation Step Confirmation Req d 9
10 Custom Display Library - Alarm Icon Presentation Priority 1 Alarm High-high or Urgent alarm state Priority 2 Alarm High priority alarm state Priority 3 Alarm Low priority alarm state Disabled alarms 10
11 Custom Display Library - Correspondence Coding Primary Loop Selected Associated Loop Highlighted 11
12 Display Hierarchy Design Process Workshops with subject matter experts Operators, supervisors, engineers Facilitator with prior HMI experience Pre Work to layout first pass as starting point Specifying Chunks or key steps of operation (L2) Approach focused on section of process that are managed Avoid narrow focus such as Heater. (eg. Reaction section includes heater) Identify Task Specific requirements needing details Managed Start Up systems, Special periodic batch operations 12 Lots of colored sticky notes
13 Display Hierarchy - Workshop results FCCU Feed U11A FCCU Rx/Regen U11B Sats Deprop Main Frac, U11C Gas Con, U12A Propylene, U13A Amine, U21B U21A Merox, U21C L2 Chrg/ Prht U11A1 Reactor, U11B1 Btms Slurry/HCO, U11C1 Pri/Sec Abs U12A1 Deethanizer, U13A1 Merox Overpress Protect, U21C1 L3 Heater, U11A2 Regen, U11B2 Ovhd/LCO, U11C2 HPR Stpr Debut U12A2 Propylene, U13A2 Htr Skin Temps FG Clr/ Stm, U11B3 Drag Streams C3/C4 Splitter U12A3 -Heat pmp U13A2a Heater SD, U11A3 Stack ESPs, U11B4 WGC, U11C3 Trm Cmp Ht Pmp U13A3 Htr ASCO Test ESP Details Comp SD, U11C5 Propylene S/D U13A4 Heater SU, U11A4 Ammonia SD S/U Circ, U11C6 Main Gas Perms Cat Additives, U11B5 Flame Scanners Air Blower U11CB6 FCC SD, U11A5 Aux Burner U11B7 FCC SD,U11A5 13
14 Display Hierarchy - Navigation Results Graphic Navigation Bar (Top row contains ALL Level 2) Navigation to Detail graphic within Level 2 Group Right Click Menu to navigate directly to a L3 Detail Right Click context menu to Detail(L3) 14
15 15 Display Hierarchy Task Specific and Popup
16 Control Displays (Level 2) Starting with Control (L2) display design first, can best set the frame work for Detail (L3) display design Iterative process between Detail (Level 3) and Control for consistent orientation will be minimized Creative License Required for Operations Specific Mental Model presentation on Control Display Review common activities with operators to ensure content requirements are captured Focus reviews on achieving proper mental model to manage this section of the process 16
17 Control Displays (Level 2) P&ID Style Detail of BFW too close to other detail Excessive Pipe detail 17 Key H2 information missing
18 18 Control Displays (Level 2) Creative Style
19 Control Displays (Level 2) Alignment Issues Key Variables not aligned Detail out of context Excessive Pipe detail 19 Missing key information
20 20 Control Displays (Level 2) Better Aligned
21 Control Displays (Level 2) - Validation Follow up observation survey of screen utilization (L2/L3 common placement across all shifts) Crude Train Control display Crude Col Control display Crude 2nd Stg Detail display Crude Debut Detail display Preflash/Heater Control display Air Preheat Detail display Vac OH Detail display Or ** What needs attention ** Crude Col Control display Or ** Used for Operating ** Air Preheat Detail display Vac Heater Control display Vac Col Control display 21
22 Console Overview Displays (Level 1) Key Process Indicators - Survey Work Leading Indicator Selection Trend Identification Panes of Glass Required to create the Canvas for overview Always Up Situation Awareness objective No plans to integrate L2/L3 navigation in L1 Displays Large Overview Screens assumed for Canvas 22
23 23 Console Overview - KPI Selection
24 Console Overview Leading Indicators Key Level, but Out flow better Leading indicator 24
25 25 Console Overview Trend Overview
26 26 Console Overview Navigation to Overview
27 Console Overview - Canvas of Console Trends or KPI Trends or KPI KPI Screen Control Display Control Display Control Display Routine Work Station Control Display Control Display Control Display 27
28 28 Console Overview Alarm Table Option
29 Lessons Learned Correspondence coding in the shapes on process displays (Control and Detail) was very effective A good navigation organization that is Always On Screen is critical Control Displays require multiple reviews with operators Good communication and Education are critical to the success of implementing KPI and /or Trend overview displays. 29
30 Lessons Learned (cont) Evolving Process for KPI displays. Items to Consider Salient Bands of operation on Bars Direction of Change iconography historical sophistication Matching Alarm coding to normal displays A complete HMI package should be rolled out at the same time. L3 and L2 roll out without L1 displays leads to Screen use culture soak. Difficult to rewire use of screens to Overview approach. Opportunities for scientific analysis between Trends and effective KPI displays 30
31 31
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