Embracing Change: High Performance Graphics to Improve Operations Water/Wastewater Case Study Standards Certification Education & Training Publishing Conferences & Exhibits Speaker: Jonathan Mitchell, PE 2016 ISA Water / Wastewater and Automatic Controls Symposium August 2-4, 2016 Orlando, Florida, USA
Presenter Jonathan Mitchell, PE Principle and Automation/GIS Group Leader working out of CDM Smith s Southcentral Regional Design Center in Dallas, Texas. BSEET and licensed Control Systems Engineer 17 years of experience in the design, construction, and integration of automation systems in water/wastewater Member of ISA and WEAT Email: mitcheljd@cdmsmith.com 2
Embracing Change - High Performance Graphics to Improve Operations High Performance Graphics (HPGs) are intended to help operations quickly identify potential problems, as well as, reduce visual distractions, nuisances and alarms. However, there is some resistance to such a perceived drastic change in the water industry. This presentation will discuss: Traditional vs High Performance HPG elements HPGs anticipated benefits/value Case studies and results Lessons learned 3
Traditional vs High Performance Graphics (HPGs) Traditional P&ID / physical layout of screens Red running / green stopped Numbers are king Sometimes animated and 3D Pipes are colored by contents High Performance Graphics are simplified and 2D Blues/grays/white for running Only alarms are hot colors Context information Comparison format 4
Traditional Graphics Overview 5
High Performance Graphics What elements make a graphic High Performance? 6
HPG Elements Contextual information Bar graphs with alarm limits; great for analyzers and analog instruments Recent history data through trending 7
HPG Elements Color Management Should be implemented for all systems, regardless of High Performance tactics Hot colors for alarms only Plants generally want running/open equipment to pop more. Used blues or dark grays for running/open, light grays or white for stopped/closed Wireframe or background color for Out-of-Service (OOS) 8
HPG Elements Alarm Management Ability to temporarily suppress or put out-of-service alarms Operator accountability who acknowledged/suppressed/oos? Some HMIs have options: Shelve Disable Suppress Prioritize and filter alarms High, Medium, Low Areas by system, plant location, controlling PLC, etc. 9
Equipment Out of Service Built-in to PLC/HMI blocks Inhibits alarms Still shows state, running/stopped Transmitters question Show current value? Show last good value? Allow to set value? 10
What do you see? 11
Benefits of High Performance Graphics Contextual information helps create: Create proactive vs reactive operations through quicker interpretation and forecasting of data Quicker response to process issues Identify equipment issues, even when intermittent Color management Quickly identify device state and alarms Alarm management Quicker response to alarms Reduction of alarms, specifically nuisance and ignored Identify faulty equipment 12
SCADA Case Studies Plant 1 HMI Application Consolidation Plant 2 Dashboard Development Plant 3 New Plant Construction 13
Plant 1 HMI Application Consolidation Existing Overview 14
Plant 1 HMI Application Consolidation HPGs Used Context Data for most transmitters Trends when applicable Inactive equipment is gray, running is blue Comparison of values 15
Plant 1 HMI Application Consolidation HP Graphic 16
Plant 1 HMI Application Consolidation HP Graphic 17
Plant 1 HMI Application Consolidation HP Graphic 18
Plant 1 HMI Application Consolidation HP Graphic 19
Plant 1 HMI Application Consolidation Alarm Management Alarm priorities; red, orange and yellow Equipment suppression tag Any operator could put equipment OOS but only maintenance could put back In Service. 20
Plant 1 HMI Application Consolidation Results Shorten operator training Operators reported being familiar with the plant operations after just one week instead of previous of one year Quicker response to alarms/issues Four screens always have the 4 main overviews Process fluctuations now had a tighter tolerance Alarms help pinpoint equipment issues Long standing faulty equipment identified through addition of alarm on items such as transmitters Identified nuisances 21
SCADA Case Studies Plant 2 Dashboard Development 22
Plant 2 Dashboard Development Dashboard 23
Plant 2 Dashboard Development Dashboard 24
Plant 2 Dashboard Development Dashboard 25
Plant 2 Dashboard Development Alarm Management Equipment suppression tag Monthly alarm history report Includes count of each alarm s occurrence Alarm reduction Nuisance alarms were quickly identified 26
Plant 2 Dashboard Development Results Management enjoys the at-a-glance capability Chemical shipments can quickly be told which tank need filling Quicker response to alarms/issues Process disruptions are obvious, even when small Plant wants more TVs but no transitions At-a-glance feature was undermined by rotating screens Desire easy comparison data 27
SCADA Case Studies Plant 3 New Construction 28
Plant 3 New Plant Construction HPGs Used Alarm count by priority Bar graphs and trends Header contains trends of all key metrics 29
Plant 3 New Plant Construction HP Graphic -Trends with SP and PV -Areas with navigation and alarm animation 30
Plant 3 New Plant Construction HP Graphic 31
Plant 3 New Plant Construction Alarm Management Priority shown by color, number, and symbol No Alarm Banner! On area navigation buttons. Operators can acknowledge alarms directly from process screens Double click Alarm Summary to navigate to the process page All equipment has Out-of-Service Operators entered a Reason 32
Plant 3 New Plant Construction Results Quick response to most important process issues Key trends on header Easy alarm management Difficult to transition from numbers to bar graphs Accepted as temporary but eventually switched some back 33
Case Studies Lessons Learned Plant staff hesitant to implement full color management HPGs can be added to any plant for any staff Varying HPGs usually finds a level of acceptance Important to identify key metrics and process areas of importance and concern Start with dashboards or overviews Alarm management can be harder to implement on existing SCADA systems 34
High Performance Graphics can help produce: Quicker interpretation and forecasting of data A proactive vs reactive operations staff Quicker response to process issues Reduction in process issues and permit breaks Quickly identify operating parameters, device state and alarms Quicker response to alarms Reduction of nuisance, ignored and alarms in general 35
QUESTIONS? For more information please see: The High Performance HMI Handbook by Bill Hollifield ISA101, Human-Machine Interfaces Jonathan Mitchell 214-354-2987 mitchelljd@cdmsmith.com 36