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:

• 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:
  • 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:
  • 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 allowing operators to input new process values.
  • User Authentication to 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.

In recent years, advancements in SCADA and HMI technology have introduced features like multi-screen layouts, cloud-based remote access, and AI-powered anomaly detection. These enhancements allow operators to monitor complex facilities from any location, integrating not only process data but also predictive maintenance insights and energy usage statistics. Modern HMI customization often involves drag-and-drop design tools, enabling faster deployment and consistent branding across all stations.

Another growing trend is responsive HMI design, where displays adapt automatically to different devices—large control room screens, tablets for field technicians, or even wearable devices for quick alerts. Integration with augmented reality (AR) and voice commands is also emerging, allowing operators to interact with equipment information hands-free while on the shop floor.

By combining these innovative capabilities with traditional best practices, SCADA HMIs can evolve into proactive decision-support systems, empowering operators not just to react to problems but to anticipate and prevent them before they escalate.

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.