SCADA Programming and Configuration: Customizing HMI Displays

Human-Machine Interface (HMI) displays in SCADA (Supervisory Control and Data Acquisition) systems serve as the visual and interactive layer between operators and industrial processes. A well-designed HMI enhances efficiency, reduces errors, and improves decision-making by presenting real-time data in an intuitive format.

Importance of Customizing HMI Displays in SCADA

✔ Enhances Operator Efficiency – Quick access to real-time data allows for faster decision-making.
✔ Reduces Human Errors – Well-structured layouts minimize confusion and misinterpretation.
✔ Improves Process Control – Operators can monitor, analyze, and adjust system parameters effortlessly.
✔ Increases Safety – Critical alarms and system alerts are instantly visible to prevent failures.

Key Elements of an HMI Display in SCADA

🔹 Process Visualization: Graphical representation of real-world processes (e.g., pumps, valves, sensors).
🔹 Data Indicators: Real-time values for pressure, temperature, flow rate, voltage, etc.
🔹 Alarms and Notifications: Visual and audible alerts for critical events.
🔹 Control Buttons: Start/stop controls for machines and processes.
🔹 Historical Trends: Graphs and charts for past performance analysis.
🔹 User Interaction: Touchscreen elements, dropdown menus, and navigation buttons.

Steps to Customize HMI Displays in SCADA

1. Define the Operational Needs

🔹 Identify what data and controls are essential for operators.
🔹 Group elements by priority (e.g., place critical alarms in top corners for visibility).
🔹 Choose an intuitive layout that matches process flow.

2. Plan the HMI Layout

✔ Divide the screen into logical sections:

✔ Best Practices:
✅ Use a dark background to reduce eye strain.
✅ Keep text readable (use contrasting colors).
✅ Group related items together (e.g., all temperature indicators on one side).

3. Add Process Graphics and Data Indicators

🔹 Use dynamic objects (e.g., animated tanks that fill based on real-time level data).
🔹 Color coding:
✔ Green: Normal operations
✔ Yellow: Warning state
✔ Red: Critical alarm
🔹 Example Visualization:

📌 Water Treatment Plant HMI:
✔ Tanks displaying real-time water levels (e.g., 85% full).
✔ Flow rate sensors updating in real-time (e.g., 1200 L/min).
✔ Pump status indicators (RUNNING / STOPPED).

4. Configure Alarms and Alerts

🔹 Color-coded Alarms:
✔ Red Blinking – Critical Failure (Immediate Action Required)
✔ Yellow Static – Warning (Check Process Parameters)
✔ Green – Normal Operation

🔹 Example Alarm Setup:

🔹 Audible and Visual Alerts:
📢 Sound alarm when a critical condition is met.
⚠ Flash icons for active warnings.
✅ Acknowledge button for operator response.

5. Integrate Historical Data and Trends

🔹 Display graphs and charts for:
✔ Temperature trends over time
✔ Energy consumption logs
✔ Machine runtime statistics

🔹 Use interactive elements:
📌 Zoomable graphs to analyze past failures.
📌 Drop-down menus to select specific timeframes.

✔ Example Trend Visualization:
📈 SCADA HMI Chart:
✔ Boiler temperature logs for past 24 hours.
✔ Comparison of normal vs. abnormal operations.

6. Enable User Interaction & Control Functions

✔ Touchscreen-Friendly Controls:
🔹 Start/Stop Buttons: For motors, pumps, and processes.
🔹 Setpoint Adjustments: Operators can input new process values.
🔹 User Authentication: Restrict access to sensitive controls based on user roles.

✔ Example:
🔹 Control Panel for HVAC System:
📌 Operators adjust temperature settings directly from HMI.
📌 "Emergency Stop" button for immediate shutdown.

Best Practices for HMI Customization

✅ Keep It Simple – Avoid cluttered screens with too much data.
✅ Prioritize Critical Data – Display the most important values in the center.
✅ Ensure Consistency – Use standardized symbols and colors across all screens.
✅ Optimize Performance – Avoid heavy graphics that slow down updates.
✅ Test Before Deployment – Run simulations to check usability and readability.

Real-World Use Cases

1. Smart Factory Automation

Scenario:
🔹 A car manufacturing plant deploys SCADA HMIs for real-time monitoring.
Results:
✔ Operators identify bottlenecks in assembly lines.
✔ Automated alerts reduce machine failures by 30%.

2. Oil and Gas Pipeline Monitoring

Scenario:
🔹 Remote monitoring of pipeline pressure and valve status via HMI.
Results:
✔ Early detection of leaks reduces financial losses.
✔ HMI trends reveal patterns for predictive maintenance.

3. Water Treatment Facility

Scenario:
🔹 SCADA HMI screens monitor water levels and chemical dosing.
Results:
✔ Reduced chemical waste by 20%.
✔ Improved water quality compliance.

Customizing HMI displays in SCADA improves efficiency, safety, and usability. By focusing on intuitive design, real-time monitoring, and automation, industries can optimize operations and reduce human errors. A well-structured HMI ensures faster decision-making, enhanced control, and greater operational visibility.