Operator Console Guidance for Faster IPCS Corrective Actions
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Solution Overview
Problem
Less experienced industrial console operators in industrial process control systems (IPCS) face difficulties in determining corrective actions for abnormal situations, such as alarms or routine maintenance, and often struggle with navigating the human machine interface (HMI) to implement these actions efficiently.
Innovation Solution
The HMI is made responsive to the current situation by presenting a selection of suggested actions with associated steps in a selectable panel, allowing the IPCS to automatically implement at least one step of the selected action, reducing the number of operator interactions required, especially for less experienced operators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the HMI requires multiple sequential interactions to implement corrective actions, then the system maintains precise control over each step, but the operator response time increases and efficiency decreases
Solution Approach 1:
The system pre-configures corrective actions with their associated HMI interaction sequences stored as templates. When an alarm occurs, the system automatically retrieves and executes the pre-defined sequence of interactions, eliminating the need for operators to manually navigate through multiple HMI screens and actions to implement corrective measures.
Solution Approach 2:
The patent introduces an intelligent software intermediary layer between the operator and the HMI system. This intermediary automatically generates and executes the sequence of HMI interactions based on the alarm type and pre-configured templates, acting as a mediator that handles the complex navigation tasks while the operator focuses on decision-making.
2Reliability
If the HMI presents detailed guidance for corrective actions, then less experienced operators can determine what actions to take, but the interface complexity increases
Solution Approach 1:
The HMI interface is segmented into distinct functional zones: an alarm display area, a separate corrective action guidance panel, and an execution area. The corrective actions are broken down into discrete, numbered steps that can be individually reviewed and executed, reducing cognitive load while providing comprehensive guidance for operators.
3Productivity
If the system automates HMI interactions for corrective actions, then operator efficiency improves, but the extent of automation increases system complexity
Solution Approach 1:
The system provides self-service automation where the HMI automatically performs the sequence of interactions based on pre-configured templates without requiring external programming or complex automation infrastructure. The automation serves itself by using the existing HMI protocols and interfaces, reducing the complexity overhead while maintaining high efficiency.
Data Source
AI summary
A method includes determining a current situation to be present in a process controlled by an industrial process control and automation system (IPCS) that includes at least one process controller coupled to input output (I/O) modules coupled to field devices including sensors and actuators that are coupled to processing equipment. Responsive to the current situation, displaying a plurality of suggested actions each including at least one step in a selectable panel in a human machine interface (HMI) associated with an operator computing system for an operator that is coupled to the process controller. Responsive to the displaying, the operator selects in the selectable panel at least one of the plurality of suggested actions (selected action). The selecting of the selected action results in the IPCS automatically implementing at least in part the step(s) associated with the selected action.