Human-Machine Interface Design for Process Control Applications

Control

Human-Machine Interface Design for Process Control

Jean-Yves Fiset

Human-Machine Interface Design for Process Control

Copyright © 2009 by ISA—Instrumentation, Systems, and Automation Society

67 Alexander Drive

P.O. Box 12277

Research Triangle Park, NC 27709

All Rights Reserved.

Printed in the United States of America.

10 9 8 7 6 5 4 3 2

ISBN: 978-1-934394-35-9

ebook ISBN: 978-1-937560-43-0

No part of this work may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of the publisher.

Notice

The information presented in this publication is for the general education of the reader. Because neither the author nor the publisher have any control over the use of the information by the reader, both the author and the publisher disclaim any and all liability of any kind arising out of such use. The reader is expected to exercise sound professional judgment in using any of the information presented in a particular application. Additionally, neither the author nor the publisher have investigated or considered the affect of any patents on the ability of the reader to use any of the information in a particular application. The reader is responsible for reviewing any possible patents that may affect any particular use of the information presented. Any references to commercial products in the work are cited as examples only. Neither the author nor the publisher endorses any referenced commercial product. Any trademarks or trade names referenced belong to the respective owner of the mark or name. Neither the author nor the publisher makes any representation regarding the availability of any referenced commercial product at any time. The manufacturer’s instructions on use of any commercial product must be followed at all times, even if in conflict with the information in this publication.

Library of Congress Cataloging-in-Publication Data

Fiset, Jean-Yves.

Human-machine interface design for process control / Jean-Yves Fiset.

       p. cm.

Includes bibliographical references and index.

ISBN 978-1-934394-35-9

1. Process control--Data processing. 2. Human-machine systems. I. Title.

TS156.8.F565 2009

670.42'75--dc22

2008037769

To Cécile, Elisabeth, and Monique, for the kindness you bring to this world. To mentors, friends and colleagues, whose questions and challenges have helped clarify my thinking and understanding.

—Jean-Yves Fiset, Eng., Ph.D.

Table of Contents

Preface

About the Author

List of Figures

List of Tables

1   Introduction

Audience

Why Design an HMI?

Organization of the Book

Paper-based Publications

2   Designing a New HMI

Understanding the User

Visual Perception

Memory

Decision-making

Internal or Mental Model

Human Error

Operator Monitoring

Linking HMI Design and System Design

Standards and Guidelines

Overall HMI Design Process

Detailed Description of the HMI Design Method

Example: Newsprint Papermaking

Planning the User-Centered Design Process

Description of the Planning Phase

Example: Carrying Out the Planning Phase

Understanding and Specifying the Context of Use

Description of the Context of Use

Example: Analyzing the Context of Use

Specifying User and Organizational Requirements

Description of User and Organizational Requirements

Example: Analyzing User and Organizational Requirements

Documentation

Producing Design Solutions

Production of Design Solutions

Example: Producing Design Solutions

Specification of the Resulting HMI

Integrating Software-based and Hardwired HMIs

Transition

References and Additional Readings

Paper-based Publications

Web-based Resources

3   Evaluating the Design Against the Requirements

Description of the Evaluation of Design Solutions

Heuristic Evaluations

Example of Heuristic Evaluation

Usability Testing

Usability Testing Example

Transition

References and Additional Readings

Paper-based Publications

Web-based Resources

4   Specifying an HMI

Standards and Guidelines

How to Specify an HMI

Ground Rules

Starting to Specify: Introduction

Specifying Common Elements: General Section

Specifying Individual Components: Detailed Specification

An Example of Specification

References and Additional Readings

Paper-based Publications

Web-based Resources

5   Improving an Existing HMI

Why Improve an Existing HMI?

Improving an Existing HMI—With Design Basis

Improving an Existing HMI—Without Design Basis

Transition

References and Additional Readings

6   Continuous, Batch, Discrete and Hybrid Applications

Designing HMIs for Different Types of Applications

Transition

7   Integrating Heterogeneous HMIs

What Integration Means

Simple Integration Strategies

Component-specific Integration Rules

Allocating Control and Monitoring Functionality to Computerized or Hardwired Panels

Using Large Screen Displays

Using Portable and Wireless Devices

Combining HMI Resources

Transition

References and Additional Readings

Paper-based Publications

Web-based Resources

8   Overall Organization of HMIs in a Control Room

Workstations

Advantages, Disadvantages and Utilization

Organizing Principles—Workstations

Organizing Principles—Additional HMI Components

Locating the HMI Components

Transition

References and Additional Readings

Paper-based Publications

Web-based Resources

9   Additional HMI Components

Operating Procedures

The Benefits of Procedures

The Development Process

Define the Purpose and Scope of the Procedures

Defining Training Requirements for Using the Procedures

Specifying How to Write, Validate and Verify Procedures

Determining the Content of Procedures

Procedure Design Principles and Rules

Structuring with Goals

Complying with and Deviating from Procedure Steps

Writing Procedure Steps

Considerations for Computerized Procedures

Integration with the HMI

Decision-Support Systems

Challenges

Integration into the HMI

Conclusion

Paper-based Publications

A   Design Guidelines and Components

Computer-based HMIs

Hardwired panels

Large screen displays (LSDs)

Glossary

Index

Preface

This book was written to share a passion: designing human-machine interfaces that enable organizations to be more efficient and safer, and users to be more satisfied about what they do.

When the author was given his first design assignment for a new human-machine interface, he realized that in spite of the academic training he had received in this area, he was still ill-equipped to produce the required design. After several years of experience and countless projects, as well as teaching numerous courses on the same topic, the author realized that it takes some key ingredients to produce good design:

A good understanding of how users comprehend a system and control it. In some cases, this understanding will even force the designer to let go of preconceived ideas about how operators work (the author had to, anyway).

A wide knowledge of the appropriate design principles and rules. Those will be both generic (applicable across domains) and specific (for a given domain, such as industrial process control). The design principles and rules are usually drawn from specific standards, guidelines and even textbooks. We do not intend to repeat all of those in this book, but rather to provide you with pointers to the appropriate sources of information.

A strong understanding of engineering design in general and of the processes used for designing human-machine interfaces in particular. It is necessary to both understand how to do the interface design itself, and, sometimes just as importantly, to understand where and how the interface design will impact the overall design project.

There are also unexpected benefits in understanding human-machine interface design. As you will discover, most equipment or even pieces of information (e.g., documents and Web pages) has an interface. Interestingly, the approach used to design those interfaces is the same as the one described in this book; usually, the differences reside in the detailed design rules, while the overall process and principles remain the same. In other words, the material in this book will be useful even outside the realm of industrial process control (in much the same way as arithmetic is used anywhere calculations are required).

You will hopefully also find that human-machine interface design offers a unique occasion to positively affect human and organizational performance, and this is often an exhilirating experience.

Finally, I hope that you will enjoy this material as much as I have enjoyed writing about it.

—Jean-Yves Fiset, Eng., Ph.D.

About the Author

Jean-Yves Fiset started his career as an electronic technologist for a process automation firm where he acquired a fair bit of practical experience on installation and troubleshooting, and explaining how those systems work. This is where he realized the importance of the interface between the users and the equipment. He then completed a bachelor of engineering (industrial engineering) and a Master of Applied Sciences (industrial engineering) specializing in human factors and artificial intelligence at École Polytechnique de Montréal. After graduating, he went to work for Atomic Energy of Canada (AECL) as a research scientist specializing in human-machine interfaces, automated emergency operating procedures and control rooms. Concurrently, he started a Ph.D., again at École Polytechnique de Montréal, where his dissertation dealt with the design of human-machine interfaces for monitoring and controlling complex systems. After leaving AECL, Dr. Fiset established Systèmes Humains-Machines Inc. (Shumac), which specializes in the analysis, design and validation of high-performance human-machine interfaces in the aerospace, nuclear, military, Web, industrial, banking and software fields. He also teaches (human factors, cognitive engineering, artificial intelligence) at the undergraduate and graduate levels since 1991. Overall, he has been involved with using and (sometimes!) understanding complex systems for nearly 30 years.

List of Figures

List of Tables

1

Introduction

This book aims to provide users and designers of industrial control and monitoring systems with an easy-to-use—yet effective—method to configure, design, and validate human-machine interfaces (HMIs). Such systems include distributed control systems (DCSs); supervisory control and data acquisition systems (SCADAs); and stand-alone units.

Distributed Control Systems (DCSs) are typically real-time, fault-tolerant systems for continuous and complex batch process applications. DCSs were developed initially for continuous flow processes that required loop, analog, and limited discrete control. A DCS, while functionally integrated, consists of sub-systems that may be physically separate and remotely located from one another.

Supervisory Control and Data Acquisition System (SCADA) is typically a generic name for a computerized system capable of gathering and processing data and applying operational controls over long distances, such as is used with power transmission and distribution and pipeline systems. SCADA systems are designed for unique communication challenges (delays, data integrity, etc.) resulting from the various media that must be used, such as phone lines, microwave, satellite, and so on. SCADA systems are usually shared, rather than dedicated.

Stand-alone Units are typically simple, embedded systems that perform pre-defined tasks, usually with very specific requirements.

This book discusses the overall HMI design process; how that process relates to system design; detailed design methods, principles, and rules for individual displays and groups of displays; and integrating both software-based and hardwired HMIs.

It also provides guidance on the design of HMIs for other, less common, yet important components, such as expert systems and electronically displayed operating procedures. With the information contained in this book, a user or designer can determine how to configure or design a whole new set of displays for a system, or how to enhance specific elements of an existing or planned HMI.

The material originates, to a large extent, from a graduate course (IND 6408 Human Factors in Process Control) and a fourth-year course (IND 4803 Cognitive Engineering for Complex Systems) that the author has been fortunate to teach for a number of years at the Department of Mathematics and Industrial Engineering of École Polytechnique de Montréal. A substantial proportion of the material is also drawn from the professional practice of the author in HMI analysis, design, and validation in domains ranging from nuclear power plants to the Web.

Audience

The primary audience intended for this book is designers and developers of HMIs; however, it will also assist project leaders and managers, engineers, and system integrators in ensuring that the systems they design will work synergistically with operators, thus leading to improved safety and productivity.

The book was also written with operators in mind. Having been in field service for a number of years, the author recognizes that operators and their supervisors optimize processes