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SCADA-02

Increased Operational

Effectiveness with

Situational Awareness

Schneider Electric - Wonderware – Date

Trends in Industrial Automation

Increased

Size and

Complexity

Increased

Data Volumes

Remote

Operations

Increased

Levels of

Automation

Staffing/

Education

Challenges


HMI Evolution/Current State

1970’s 1980’s 2000’s Future


Key Principles - Distracting and Irrelevant Detail

●Although pleasant to

see, much of this graphic

is irrelevant to the control.


Key PrinciplesDistracting and Irrelevant Detail

●Although pleasant to

see, much of this graphic

is irrelevant to control the

process.

●These are the only

objects providing

information to the

operator


Impact of Human Error

The average percentages shown had the following:

•People and work Context Factors: 35% - 58%

•Equipment Factors: 30% - 45%

•Process Factors: 3% - 35%

Abnormal Situation

A disturbance or series of

disturbances in a process

that cause plant

operations to deviate from

their normal operating

state.

Source: ASM Consortium

Abnormal Situation Causes

Human Error

Equipment Failure

Process

42%

36%

22%


Situational Awareness

The perception of

environmental elements

with respect to time

and/or space, the

comprehension of their

meaning, and the

projection of their status.


Creating the Business Case


Safe and Reliable Control

●Poorly performing alarm systems AND HMIs are

contributing factors to major accidents and poor

operating performance.

●Proper Alarm System Management and Alarm System

Performance is essential to maximum-efficiency

operations.

●There are multiple contributing factors:

Alarm Management

Human Machine Interface

Control Loop

Performance


Measurable Costs/Value

Raw Materials Process Products/Services

En

erg

yW

aste

$

$

$

$

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


Goal Oriented Design

●Common Mistake – The System is the Goal.

Goal

Directed

Task

Analysis


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.

Display structure


Reduced Navigation

Start-up/Shut Down Info

NO MASTER FUEL TRIP

PURGE COMPLETE

FUEL GAS ON

ABC RESET

ABC MODE MANUAL

IGNITOR HEADER PERMISSIVES SATISFIED

GAS HEADER PERMISSIVES SATISFIED

Navigation Zone

STM F BFW F

DL

BP

FD (P)

% O2

STM

T

Air F

IGN

B2IGMN

BURNER START

REGISTER OPEN

MODE AUTO

IGNITOR ON

IMPELLER OUT

OIL BURNER ON

SAB 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

ssure

(P

SIG

)

Time (min)10 20 30 SAT Steam

0

100

200

300

400

500

600

700

800

900

1000

Sat Steam ROC(oC/hr)

Last hr: 0.00

Current: 0.00

SH Steam ROC

(oC/hr)

Target: 0.00

Current: 2.00

To 100oC Drum

Bottom Temp (oC)

Target: 0.00

Current: 2.00

Last hr: 0.01

Drum Press ROC

(psig/min)

Last hr: 0.20

Current: 0.00

Start-up/Shut Down Info

NO MASTER FUEL TRIP

PURGE COMPLETE

FUEL GAS ON

ABC RESET

ABC MODE MANUAL

IGNITOR HEADER PERMISSIVES SATISFIED

GAS HEADER PERMISSIVES SATISFIED

Navigation Zone

STM F BFW F

DL

BP

FD (P)

% O2

STM

T

Air F

IGN

B2IGMN

BURNER START

REGISTER OPEN

MODE AUTO

IGNITOR ON

IMPELLER OUT

OIL BURNER ON

SAB 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

ssure

(P

SIG

)

Time (min)10 20 30 SAT Steam

0

100

200

300

400

500

600

700

800

900

1000

Sat Steam ROC(oC/hr)

Last hr: 0.00

Current: 0.00

SH Steam ROC

(oC/hr)

Target: 0.00

Current: 2.00

To 100oC Drum

Bottom Temp (oC)

Target: 0.00

Current: 2.00

Last hr: 0.01

Drum Press ROC

(psig/min)

Last hr: 0.20

Current: 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 guide attention

– Your eye is automatically drawn to

colored objects

• This is called the “pop out” effect

– Now try this one…

Color is a powerful way to guide attention

– Your eye is automatically drawn to

colored objects

• This is called the “pop out” effect

– Find the the “L”s and “I”s

in this picture…


Color and Attention

●Situational Awareness focused displays take advantage of the “pop out”

effect to guide operators’ attention to values that are in alarm

Click

and

watch

for the

alarm

…


Different tastes…Reactor 1

Thionite

Mid-Run

ON

CLEAR

Prod:

State:

Agit:

Locks:

Run Plan:

Actual:

IN OUTBalance

Menus

Main

Menu

Feed

Sys

Aux

Sys

Reactor

1

L2

Trend

Control

Comp A Comp B

72.0

80.0

2 HR

Cool CPC CRM

Rate

Reactor 2

CRM-114

Mid-Run

ON

CLEAR

Prod:

State:

Agit:

Locks:

Run Plan:

Actual:

Balance

Comp A Comp B

60.0

68.0

2 HR

Cool CPC CRM

Rate

IN OUT

Hydrog A

Bed

A1

Bed

A2

Suct Dsch

OK

OK

OK

CLEAR

VIB:

BRG:

OIL:

Locks:

Cycle

Comp A

470

500

F

L

O

W

2 HR

Hydrog B

Bed

B1

Bed

B2

Suct Dsch

OK

OK

OK

CLEAR

VIB:

BRG:

OIL:

Locks:

Cycle

Comp B

470

500

F

L

O

W

2 HR

Alarms:

ACK

UNACK

Toggle

List /Summary

P1

0

0

P2

1

0

P3

2

1

P4

4

1

Reactor

2

Hydrog

A

Hydrog

B

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

Thionite

Mid-Run

ON

CLEAR

Prod:

State:

Agit:

Locks:

Run Plan:

Actual:

IN OUTBalance

Menus

Main

Menu

Feed

Sys

Aux

Sys

Reactor

1

L2

Trend

Control

Comp A Comp B

72.0

80.0

2 HR

Cool CPC CRM

Rate

Reactor 2

CRM-114

Mid-Run

ON

CLEAR

Prod:

State:

Agit:

Locks:

Run Plan:

Actual:

Balance

Comp A Comp B

60.0

68.0

2 HR

Cool CPC CRM

Rate

IN OUT

Hydrog A

Bed

A1

Bed

A2

Suct Dsch

OK

OK

OK

CLEAR

VIB:

BRG:

OIL:

Locks:

Cycle

Comp A

470

500

F

L

O

W

2 HR

Hydrog B

Bed

B1

Bed

B2

Suct Dsch

OK

OK

OK

CLEAR

VIB:

BRG:

OIL:

Locks:

Cycle

Comp B

470

500

F

L

O

W

2 HR

Alarms:

ACK

UNACK

Toggle

List /Summary

P1

0

0

P2

1

0

P3

2

1

P4

4

1

Reactor

2

Hydrog

A

Hydrog

B

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 signaling in the

HMI displays


Navigation Badges

Reactor 311 2 1 3

Reactor 323

Reactor 332

Overview1 4 1 6


Equipment Meters/Polar Stars Dashboard Tools

Wonderware Situational Awareness

Symbol Library

• Agitator/Settler

• Equipment

Status

• Feeder

• Hand Switch

Selector

• Heat

Exchanger/Fan

• Loop Block

• Miscellaneous

Equipment

• Multistage Pump

• Numeric Data

Block

• Output Bar

• Parallel Control

Valve

• Pump/Blower/

Rotary Valve

• Rotating

Equipment

• Sequence

Button

• Tank/Vessel

• Thickener

• Valve/Damper

• Invisible Profile

Meter

• KPI Bar

• Meters

• Multi-Level Meter

• Rake Height

Meter

• RPM Meter

• Meter Connector

• Small Flow

Tracker

• Polar Star 3

Spoke

• Polar Start 4

Spoke Diamond

• Polar Start 4

Spoke Square

• Polar Star 6

Spoke

• Polar Star 8

Spoke

• Bar Chart

• Box Chart

• Bullet Graph

• Column Chart

• Column Chart

Pairs

• Column Chart

Trips

• Deviation Chart

• Parallel

Coordinates

Chart

• Pie Chart

• Stacked Column

Chart

• Stacked Column

Chart Alarms

• Target Graph

• Value

Comparison

Chart

• Variable

Monitoring Bars

• Win Loss Chart


Data vs Information

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 without

context

How far is it from

setpoint?

Is it getting close to

alarming?

Is it inside the normal

operating range?At best, this is inconvenient – but during an upset it can lead

to slower response times and cause costly errors


Analog Meters

How can we avoid forcing people to calculate these things in their heads?

● By using a visual representation – such as an analog meter…

This is a

pressure meter

Different types of

values have

slightly different

meter shapes

All meters

include visual

representations

of the PV and

the related

reference values

mis

989.7kPa

PI-4105

PI-4105PI-4105

kPaXXXXX

PI-4105

mis

HHAL

HAL

SP

PV

LLAL

LAL


mis

123.4m3/h

FIC 123

FIC 123

C

FIC 123m3/h

C

XXXXX

FIC 123

mis

Meter Components

PV in ideal

range

PV near edge

of ideal range

– watch more

closely

PV outside of

ideal range –

consider

taking action

Glance Test

When you click, an example will appear

briefly at the far right of the screen – see if

you can tell whether the PV is inside the

optimal range or not

Click

again…

And again…

Each example was only

shown for ½ of a second


Trends

●Trends are effective for attaining Level 3 SA – Projection.

SparklinesTrend Tail


Multivariate Analysis


Level 3 Display


More…


Benefits…Task With Traditional

HMI

With High

Performance HMI

Result

Detecting

Abnormal

Situations before

alarms occur

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

Success rate in

handling abnormal

Situation

70% 96% 37% over base

case

Time to complete

abnormal situation

tasks

18.1 min 10.6 min 41% reduction


Evolving Industrial Operations

Past Future

Process Parameters Situational Awareness

Labor Resources Information Craftsmen

Reactive Operations Proactive Operations

Operating a Process Real Time Business Management


The Future is Now

2014

Situational

Awareness

2014

ww hmi scada-02 - wonderware system · pdf fileoperating performance. proper alarm system...

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