VZ02 - How to Improve Plant

Operations Through Better HMI

Graphics
Agenda

1 2 3 4
Introduction Problems Solutions References
Agenda

1 2 3 4
Introduction Problems Solutions References
What is HMI?
User interface to monitor and control machine or system

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Control Rooms
User interface to monitor and control machine or system

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Texaco Pembroke (1994)
Well designed HMI
• Prevent shutdowns
• Improve safety
• Improve efficiency

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BP Amoco, Texas City (2005)

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Agenda

1 2 3 4
Introduction Problems Solutions References
Information Overload
▪ Large amounts of process data

▪ Ineffective displays

▪ Inappropriate use of graphics

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Too Much Prettiness

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Situational Awareness
▪ Awareness of what is happening

▪ Understanding process state now

▪ Understanding likely state in future

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Why should we care
High Return on Investment

▪ Shutdowns + Accidents costly ▪ Well designed HMI

▪ Injuries ▪ Prevent shutdowns

▪ Downtime ▪ Improve safety

▪ Productivity ▪ Improve efficiency

▪ Insurance ▪ Lower training costs

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Agenda

1 2 3 4
Introduction Problems Solutions References
Standards to reference ANSI/ISA-101.01-2015
CONTINUOUS WORK PROCESSES
MOC Audit Validation

ENTRY ENTRY

New System New Display

Major Changes Display Changes
DESIGN IMPLEMENT OPERATE Continuous
Improvement
Console Design Build Displays In Service
Philosophy

REVIEW
HMI System Build Console Maintain
Style Guide Design
Test Decommission

Toolkits User, Task,

Functional Train
Requirements
Commission
Continuous Display Design
Verification
Improvement

ANSI/ISA-101.01-2015 - “Human Machine Interfaces for Process Automation Systems”

▪ WG1 – HMI Philosophy and Style Guide
▪ WG2 – HMI Usability and Performance
▪ WG3 – HMI for Mobile Devices
▪ WG4 – HMI for On-Machine Applications

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Standards to reference – ISA18.2
▪ ANSI/ISA-18.2-2016 - Management of Alarm Systems for
the Process Industries
▪ ISA-TR18.2.2-2016 - Alarm Identification and
Rationalization
▪ ISA-TR18.2.3-2015 - Basic Alarm Design
▪ ISA-TR18.2.4-2012 - Enhanced and Advanced Alarm
Methods
▪ ISA-TR18.2.5-2012 - Alarm System Monitoring,
Assessment, and Auditing
▪ ISA-TR18.2.6-2012 - Alarm Systems for Batch and
Discrete Processes
▪ ISA-TR18.2.7-2017 - Alarm Management When Utilizing
Packaged Systems

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The User
▪ Roles, functions, expertise
▪ Focus on primary user
▪ Don’t forget others

▪ Goals and Tasks

▪ Observation + interviews
▪ Identify information + context

▪ Human limitations + capabilities

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Mental Model

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The Environment
▪ Technology
▪ Screen type
▪ Equipment
▪ PPE
▪ Workstation
▪ Cabinet
▪ Audience
▪ Conditions
▪ Lighting
▪ Noise

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The Strategy
▪ Building upon findings from User and Environment

▪ Documentation

▪ Organization

▪ Layout

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Documentation
▪ HMI Philosophy
▪ Best practices
▪ Life cycle

▪ HMI Style Guide

▪ Key principles
▪ All aspects covered
▪ Highly detailed
▪ New standards

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Organization
▪ User’s Goals + Tasks

▪ Match User’s Mental Model

▪ Related Information Together

▪ Navigation Paradigm

▪ Progressive Disclosure (4 levels)

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Navigation
▪ Main

▪ Related

▪ Consistency

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Layout
▪ Not P&ID copies

▪ Match Mental Model

▪ Remove What’s Unnecessary

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Standards to reference ANSI/ISA-101.01-2015

908230498230497509872349857109821340987098
742305987109821340987209875098172309487213
098470982498098234590829809817230948712349
802498067456870983473460983434580938094533
453085489009737098139158248813198349801398
52340968702945867092

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Standards to reference ANSI/ISA-101.01-2015

908230498230497509872349857109821340987098
742305987109821340987209875098172309487213
098470982498098234590829809817230948712349
802498067456870983473460983434580938094533
463085489009737098139158248813198349801398
52340968702943867092

PUBLIC | TechEd | #ROKLiv e | Copy right ©2019 Rockwell Automation, Inc. 26

Standards to reference ANSI/ISA-101.01-2015

908230498230497509872349857109821340987098
742305987109821340987209875098172309487213
098470982498098234590829809817230948712349
802498067456870983473460983434580938094533
463085489209737098139158248812198349801398
52340968702943867092

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Situation Awareness
▪ The displays of an HMI’s primary objective is to support the user’s mental model of the plant or
process.
▪ Situation awareness means:
▪ being aware of what is happening in the process,
▪ understanding the process state now,
▪ understanding the likely process state in the future.
▪ The HMI should support the awareness and understanding of the system and process status.
▪ When the process is functioning as expected, the display should exhibit minimal sensory
stimuli.
▪ As the process deviates from expectations, the HMI should provide visual and/or audible
signals with appropriate salience for the situation.

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Situation Awareness
What can we do to increase situation awareness

By NOT doing this…

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User Sensory Limits
▪ Design the HMI to the user’s sensory limits.
▪ Color impairment, hearing loss.
▪ Red/Green color impairment – 7 to 10% of males.
▪ What can we do……

Normal Protanopia Deuteranopia Tritanopia

Red-Green Blue-Yellow

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Color
Where’s Wally on an HMI Graphic

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Color

Stopped Running

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Color

Don’t do this… Instead, do this…

Space for DCS Specific “Banner” feature if used

0 1 1 2 1 3 1 4

Reserved Faceplate Zone

Filters Influent Filters When any item on the screen is selected,

Combined Chlorine the faceplate for that item appears in the
Combined Chlorine Effluent pH Turbidity Temp
Effluent Residual reserved area.
Turbidity Residual
Flow All control manipulation is accomplished
through the standardized faceplates.

Filters 0.03 1.25 6.17 8.10 1.17 0.28 20.2 Lab

NTU Mg/L MGD pH Mg/L NTU °C

Wash Water

Reservoir
Distribution
System

3
P101 P102 P103

Wash Water
RUNNING RUNNING RUNNING to Filter 1
Level Effluent Flow V105
Wash Water
to Filter 2
691.3 CM 210 MGD 374
V103 2 MGD OPENED
Wash Water
to Filter 3
Wash Water Flow
V101 B101
Wash Water
to Filter 4
Air Intake CLOSED
CLOSED Air Scour to
Filter 1
STOPPED V104
Air Scour to
V102 B102 Filter 2
210
Air Scour to
Air Intake OPENED scfm Filter 3
Air Supply Flow
OPENED Air Scour to
Filter 4
RUNNING

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Color
▪ The most noticeable colors of a display should be used for the information that is most
important.
▪ In accordance with the facility’s alarm philosophy and ANSI/ISA-18.2-2009, colors used for
alarm presentation should be reserved and not used for any other purpose.
▪ Red, Orange,Yellows (warm colors) use them only for abnormal situations in order to quickly
draw the operators attention to them.
▪ Flashing spinning things – agitator blades spinning – NO!

35%

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Not Just Color – Contrast and Edge Detection

2 1 4
ON ON ON

2 1 4
ON ON ON

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Density of displayed information

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Background-foreground interactions
▪ The background should be an unsaturated or neutral color (e.g., light gray) in order to limit
chromatic distortions and ensure the salience of the information displayed.
▪ Foreground and background color combinations should provide sufficient contrast.
▪ The background color should be selected to provide acceptable and sufficient contrast in
expected ambient lighting conditions.

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 User Cognitive Limits

▪ The cognitive processes that transform, reduce, store, recover and use sensory input are
important to human performance.

Environment:
Input

Retrieval
Attention
Sensory Short-Term Long-Term
Memory Memory Memory

Rehearsal
Rehearsal
Loop
Recall

▪ A user’s performance and the underlying cognitive processes are affected by the workload level,
situation awareness, and task complexity, each of which can be optimized by the design of the
HMI.
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Standards to reference – ISA18.2

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 Standards
User reference – ISA18.2
to Limits
Cognitive

User cognitive limits

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ISA101 Section 5.3
User Cognitive Limits – What we can do
▪ Design to the user’s mental model.
▪ Group relevant data together.
▪ Provide key data that is relevant to the user’s roles and responsibilities.
▪ Do not clutter the graphic with data that is only required intermittently.
▪ Put relevant Data inside of objects then the user can assimilate the information as one
chunk of data.
▪ 7 plus or minus 2 chunks of information retained
▪ Millar’s Law (4 chunks more recent (Cohen)).

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Display Styles and Overall HMI Structure

Provide an overview of the operator’s entire span of responsibility.

Level 1
Overview Display

Operator’s primary operating display during normal operations for Level 2 Level 2
routine changes and monitoring.
Process Unit Control Display Process Unit Control Display

Used for non-routine operations. Should provide sufficient Level 3 Level 3

information to facilitate process diagnostics.
Process Unit Detail Display Process Unit Detail Display

Interlocks, Diagnostics, Help and Documentation. Usually Level 4 Level 4

faceplates or popups.
Process Unit Support display Process Unit Support display

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Level 1 Display
▪ Used to provide an overview or summary of the key parameters,
alarms, calculated process conditions of an operator’s entire span of
control on one display.
▪ On larger systems, they could span multiple screens provided they
are all visible at the same time.
▪ Broadest scope and lowest level of process or system detail.

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Level 1 Display
Current Batch Chocolate Chip Batch ID MQ19537
1 1 1 2 0 3 0 4
Time to Run 2 Hours 54 Minutes CIP Status Ready
Mixer Depositor Oven Cooler

119.2 192.1 194.7 195.9 195.7 195.6 194.1 192.4 156.1 119.7
4701 RPM 210 NM Psi °C °C °C °C °C °C °C °C °C

Wrapper Packer Palletizer

Infeed
Butter Salt BiCarb Sugar Water Cocoa Vanilla

Infeed
80.8 71.7 56.2
OEE OEE OEE Mixer

Depositor

Oven

Cooling

47 63 12 46 61 49 61 Wrapper
1
% % % % % % %
190 67 0 Packer
2 Units/Min Units/Min Units/Min Palletizer

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Level 2 Display
▪ Best described as high level process displays.
▪ Typically contain more detail than the level 1 displays.
▪ Should be the operator’s primary operating display during normal operations for
routine changes and monitoring.
▪ Should be task based to allow the operator to perform tasks using a limited
number of displays and minimal navigation.
▪ Provide easy navigation to greater detail provided on the level 3 and 4 displays.

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Level 2 Display

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 Level 3 Display
▪ Best described as system or subsystem detail displays.
▪ Typically contain more detail than the associated level 2 displays.
▪ Used for non-routine operations such as line changes, equipment switching, or complex routine tasks.
▪ Provide sufficient information to facilitate process diagnostics.
▪ Task based to allow the operator to perform tasks using a limited number of displays and minimal
navigation.
▪ Depending on the specific process, plant, display designs, and overall display hierarchy, this level 3
information may be combined in a level 2, or level 4 presentation.

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Level 3 Display
Space for DCS Specific “Banner” feature if used

0 1 1 2 1 3 1 4

Reserved Faceplate Zone

Filters Influent Filters When any item on the screen is selected,

Combined Chlorine the faceplate for that item appears in the
Combined Chlorine Effluent pH Turbidity Temp
Effluent Residual reserved area.
Turbidity Residual
Flow All control manipulation is accomplished
through the standardized faceplates.

Filters 0.03 1.25 6.17 8.10 1.17 0.28 20.2 Lab

NTU Mg/L MGD pH Mg/L NTU °C

Wash Water

Reservoir
Distribution
System

3
P101 P102 P103

Wash Water
RUNNING RUNNING RUNNING to Filter 1
Level Effluent Flow V105
Wash Water
to Filter 2
691.3 CM 210 MGD 374
V103 2 MGD OPENED
Wash Water
to Filter 3
Wash Water Flow
V101 B101
Wash Water
to Filter 4
Air Intake CLOSED
CLOSED Air Scour to
Filter 1
STOPPED V104
Air Scour to
V102 B102 Filter 2
210
Air Scour to
Air Intake OPENED scfm Filter 3
Air Supply Flow
OPENED Air Scour to
Filter 4
RUNNING

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Level 4 Display
▪ Level 4 displays are characterized as:
▪ providing operating procedures for individual pieces of equipment,
▪ providing help information for equipment control and diagnostics,
▪ containing detailed safety shut downs,
▪ containing interlock and permissive information.
▪ Most likely to be a faceplate

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Navigation

Don’t do this… Instead, do this…

Overview Tank 1 Tank 2 Generator

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Navigation
▪ Example Navigation performance

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Error Avoidance Methods
▪ Can be as simple as “Are you sure?” prompt
▪ Electronic Signature

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What can we do?
▪ Think of the end User.
▪ Stop the clutter.
▪ Design for Situation Awareness.

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 SAY SITUATION AWARENESS
Navigation ONE MORE TIME

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 What we can do
▪ Situation awareness means
▪ Being aware of what is happening around you.
▪ Understanding what that information means to you now.
▪ Understanding what that information means to you in the future.

▪ Situation awareness relates to the goals and objectives of a specific job or

function.

▪ Designers and engineers form in their heads a different mental model of the
process than an operator.

▪ By understanding how operators select and use goals, designers can better
understand how information is perceived. Without understanding the user’s
goals on Situation Awareness, the information presented has no meaning.
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Increasing Situation Awareness : What we can do
▪ Avoid only numeric value, even with a high and low value
the data requires processing.
▪ If it has to be a numeric value…
▪ Consider the units % of a tank rather than litres.
▪ Make the Font big enough to read easily.
▪ Make the Font color a different color than the text
labels.
▪ Don’t put values in fancy 3D sunken/raised boxes.

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Increasing Situation Awareness : What we can do
Sparkline

Name
Value

High limit

Current value
Low limit
Units

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Increasing Situation Awareness : What we can do
Trends
▪ Provides assistance for Level 3 SA projection of future
status through the use of trend displays.
▪ The operator can then see where the process is heading.
▪ The operator can then be proactive and recognize
impending problems, rather than being reactive and
responding to alarms and problems after the fact.
▪ Use trending with thought. For instance a trend with 8
trends on it is confusing and takes a long time to analyze.

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Increasing Situation Awareness : What we can do
Trends
Name Units Setpoint

High limit Current value

Pen marker
Scale
Grid Low limit

Timespan

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Increasing Situation Awareness : What we can do
Multi line trends

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Increasing Situation Awareness : What we can do
Tank levels
▪ Is the level rising or falling?
▪ Is the direction up or down?

53%

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Increasing Situation Awareness : What we can do
Naming

Real Names

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Increasing Situation Awareness : What we can do
Permissive tables

Ellipsis reveal link to

further details, e.g.
Navigation to the HMI
display where the user
can resolve the
Conditions that must be condition
resolved are
differentiated,
highlighted and float to
the top

Fulfilled Conditions
move to the bottom and
are grayed out

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Increasing Situation Awareness : What we can do
Pattern Recognition
▪ Involves identification of faces, objects, words, melodies, etc. The visual
system does more than just interpret forms, contours and colors. Pattern
recognition refers to the process of recognizing a set of stimuli arranged in a
certain pattern that is characteristic of that set of stimuli.
▪ Pattern recognition does not occur instantly, although it does happen
automatically and spontaneously.
▪ Pattern recognition is an innate ability of animals.
▪ The human brain is built around pattern recognition,
▪ We recognise patterns automatically, for example faces, rooms, melodies so
why not use what our brains do automatically in an HMI graphic.

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Increasing Situation Awareness : What we can do
Pattern Recognition
▪ 12 Numbers on a screen take time to interpret.
▪ 12 Trends on a trend become confusing.
▪ Filled Radar Plot
▪ The radar plot is a graph that consists of a sequence of equi-angular
spokes, called radii, with each spoke representing one of the variables.
▪ The data length of a spoke is proportional to the magnitude of the variable
for the data point relative to the maximum magnitude of the variable across
all data points.
▪ Scaling of each of the axis can generate a pattern for normal range of
variables. For example 6 values can be scaled to form an equilateral
hexagon when the plant is running under normal conditions.
▪ A change in the pattern is very quickly identified by the operator.
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Increasing Situation Awareness : What we can do
Pattern Recognition - Radar Chart
284.1 278.3 284.1 304.2
Zone 6
(°C)
Zone 1
(°C)
Zone 6
(°C)
1 Zone 1
(°C)

Alarm High

Alarm Low

Value

276.3 268.1 276.3 268.1

Zone 5 Zone 2 Zone 5 Zone 2
(°C) (°C) (°C) (°C)

Normal High

Normal Low

263.1 274.4 263.1 274.4

Zone 4 Zone 3 Zone 4 Zone 3
(°C) (°C) (°C) (°C)

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Increasing Situation Awareness : What we can do
Gauges

Normal Low
277.9 283.7 280.2
Zone 1 Zone 2 Zone 3
(°C) (°C) (°C)
Normal High

Current Value

1
2
284.1 46.1 26.3
Zone 4 Zone 5 Zone 5
(°C) (°C) (°C)

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Rockwell Automation’s HMI Style Guide

Rockwell Automation PCDC website

PDF version
https://literature.rockwellautomation.com/idc/groups/literature/documents/wp/proces-wp023_-en-p.pdf
KBAID with Word version – Answer ID 1086840

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PlantPAx FactoryTalk View SE
Available on the PCDC
Search “Process object”

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Studio 5000 View Designer
Available on the PCDC
Search “power automation”

See them at Sessions

Labs
VZ01 : VZ06 : VZ11 : VZ15
Demo
V5

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MightyQ Cookie Line Converted to a level 1 Display

PUBLIC | TechEd | #ROKLiv e | Copy right ©2019 Rockwell Automation, Inc. 71

MightyQ Cookie Line Converted to a level 1 Display
Current Batch Chocolate Chip Batch ID MQ19537
1 1 1 2 0 3 0 4
Time to Run 2 Hours 54 Minutes CIP Status Ready
Mixer Depositor Oven Cooler

119.2 192.1 194.7 195.9 195.7 195.6 194.1 192.4 156.1 119.7
4701 RPM 210 NM Psi °C °C °C °C °C °C °C °C °C

Wrapper Packer Palletizer

Infeed
Butter Salt BiCarb Sugar Water Cocoa Vanilla

Infeed
80.8 71.7 56.2
OEE OEE OEE Mixer

Depositor

Oven

Cooling

47 63 12 46 61 49 61 Wrapper
1
% % % % % % %
190 67 0 Packer
2 Units/Min Units/Min Units/Min Palletizer

PUBLIC | TechEd | #ROKLiv e | Copy right ©2019 Rockwell Automation, Inc. 72

That guy just told us how to improve our Situation
MightyQ Cookie Line Converted to a level 1 Display
Awareness

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Agenda

1 2 3 4
Introduction Problems Solutions References
References
▪ ANSI/ISA-101.01-2015 - Human Machine Interfaces for Process Automation
Systems
▪ ISA18.2 2016 – Alarm Rationalization and Management
▪ Designing for People – ISBN 9781539808008
▪ ASM Consortium Guidelines – ISBN 978-1440431647 - Effective Console
Operator HMI Design
▪ High Performance HMI Handbook - Hollifield et al
▪ Information Dashboard Design - Stephen Few
▪ American Fuel & Petrochemical Manufacturers AM-15-07
▪ Operator Situation Awareness & Delivering ASM-Compliant High Performance
HMIs: Failure Modes and Success Factors
▪ Rockwell Automation® Library of Process Objects
Available from the Product Comparison Download Website
▪ Rockwell Automation Whitepaper – Human Machine Interfaces for Distributed
Control Systems:
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Thank you

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