Improving Plant Monitoring System
Improving Plant Monitoring System
The primary goal of designing the Plant Monitoring Dashboard was to simplify real-time sensor data analysis in oil and gas plants, enabling informed decision-making and improving operational efficiency.
The primary goal of designing the Plant Monitoring Dashboard was to simplify real-time sensor data analysis in oil and gas plants, enabling informed decision-making and improving operational efficiency.
Note: This case study is more than just screens — it’s a deep-dive into the UX process. From research and problem framing to mapping user flows, wireframing, and applying UX laws like Hick’s, Miller’s, and Fitts’s, every step was grounded in design rationale.
The goal here is not only to present a solution, but to show the thinking behind the design — how user behavior, usability principles were balanced to create a system that is both effective and intuitive.
So, take your time, read with patience, and enjoy the journey of how research, UX strategy, and design laws shaped this project into a real problem-solving experience.
Note: This case study is more than just screens — it’s a deep-dive into the UX process. From research and problem framing to mapping user flows, wireframing, and applying UX laws like Hick’s, Miller’s, and Fitts’s, every step was grounded in design rationale.
The goal here is not only to present a solution, but to show the thinking behind the design — how user behavior, usability principles were balanced to create a system that is both effective and intuitive.
So, take your time, read with patience, and enjoy the journey of how research, UX strategy, and design laws shaped this project into a real problem-solving experience.
Note: This case study is more than just screens — it’s a deep-dive into the UX process. From research and problem framing to mapping user flows, wireframing, and applying UX laws like Hick’s, Miller’s, and Fitts’s, every step was grounded in design rationale.
The goal here is not only to present a solution, but to show the thinking behind the design — how user behavior, usability principles were balanced to create a system that is both effective and intuitive.
So, take your time, read with patience, and enjoy the journey of how research, UX strategy, and design laws shaped this project into a real problem-solving experience.
What did I do?
What did I do?
Strategy
Wireframing
UX Research
UX Design
High-Fidelity Prototyping
Team collaboration
Problem
Statement
Problem Statement
The oil & gas industry relies heavily on real-time monitoring, but existing plant monitoring solutions are often cluttered, complex, and not user-friendly. Client in the oil and gas industry needs a custom dashboard that simplifies real-time sensor data. The dashboard should enable users to compare and analyze ongoing processes and gain insights from historical trends.
The dashboard should support the following five sensor data types:
• Temperature
• Oil Flow Rate
• Pressure
• Tank Level
• Choke Open Percentage
Requirements:
• Real-Time Data Comparison: Users can select and compare data from several sensors.
• Insights & Analytics: Provide analytical insights based on the data trends
• Visualization: Offer graphs and tabular format for users to compare data points better.
The oil & gas industry relies heavily on real-time monitoring, but existing plant monitoring solutions are often cluttered, complex, and not user-friendly. Client in the oil and gas industry needs a custom dashboard that simplifies real-time sensor data. The dashboard should enable users to compare and analyze ongoing processes and gain insights from historical trends.
The dashboard should support the following five sensor data types:
• Temperature
• Oil Flow Rate
• Pressure
• Tank Level
• Choke Open Percentage
Requirements:
• Real-Time Data Comparison: Users can select and compare data from several sensors.
• Insights & Analytics: Provide analytical insights based on the data trends
• Visualization: Offer graphs and tabular format for users to compare data points better.
Research
Research
After giving some time to understand all aspects of the problem statement, I started my research with broad keywords like “PI (Plant Information) system” and “Oil and gas plant software”, To understand what a plant information or monitoring system is, how it works, and what choke open percentage is, etc., and then narrowed it down with findings. With the help of Google, I found answers and solutions that’s similar to what was asked.
After giving some time to understand all aspects of the problem statement, I started my research with broad keywords like “PI (Plant Information) system” and “Oil and gas plant software”, To understand what a plant information or monitoring system is, how it works, and what choke open percentage is, etc., and then narrowed it down with findings. With the help of Google, I found answers and solutions that’s similar to what was asked.
Insights
Solutions in Oil and Gas Industry are majorly limited because it’s a complex industry, and a gap between designers and users. Each plant is different at some level ,that’s why scalability of solution and integration of different sensors in one system is concern.
Understanding How PI System Works?
Understanding How PI System Works?
PI system collect data from different sensors, then store for historical trends analysis, manage it for example notify user about an alert etc., and present it in a format understandable to user for analysis or for integration with other cloud or IOT service or to train a ML model
PI system collect data from different sensors, then store for historical trends analysis, manage it for example notify user about an alert etc., and present it in a format understandable to user for analysis or for integration with other cloud or IOT service or to train a ML model
The oil and gas industry is broken down into three segments:
Upstream
This segment focuses on the exploration and production of oil and gas, involving activities such as locating underground reserves, drilling wells.
Midstream
This segment takes over, handling the transportation, storage, and wholesale marketing of crude or refined petroleum products.
Downstream
This segment is responsible for refining crude oil and processing natural gas, as well as distributing the final products to consumers.
Upstream
This segment focuses on the exploration and production of oil and gas, involving activities such as locating underground reserves, drilling wells.
Midstream
This segment takes over, handling the transportation, storage, and wholesale marketing of crude or refined petroleum products.
Downstream
This segment is responsible for refining crude oil and processing natural gas, as well as distributing the final products to consumers.
Why current design fails?
Why current design fails?
Found some similar solutions, but they are lacking in visual design and fundamentals of UX. The design is not user-centric & intuitive. I didn’t got chance to use this software but from webinars, demo videos and catalogues they gave me a good idea about their working and problem they address etc.
Found some similar solutions, but they are lacking in visual design and fundamentals of UX. The design is not user-centric & intuitive. I didn’t got chance to use this software but from webinars, demo videos and catalogues they gave me a good idea about their working and problem they address etc.
7 billion USD
Current Market Value
9 billion USD
Market value by 2031 (as expected)
3.68%
Growth Rate
Design Solution
Design Solution
Users: From plant managers to workers, all will use this program. Complexity is tried to make as low as a person who doesn’t use digital experience much must also understand what is what, and what it does.
Users: From plant managers to workers, all will use this program. Complexity is tried to make as low as a person who doesn’t use digital experience much must also understand what is what, and what it does.
• Home-screen, which displays key plant locations, their performance metrics, and quick CTAs.
• Next is a Plant Overview Screen which shows information of refineries in a diagram & tabular view for more clarity
• Then comes the Main Dashboard screen, I divided the screen into graphical & tabular view making it more intuitive.
• Detailed Sensor View: Historical trends, filters, and comparison across multiple sensors.
• Comparison Screen: Graph + table combination for cross-plant or cross-component analysis.
• Home-screen, which displays key plant locations, their performance metrics, and quick CTAs.
• Next is a Plant Overview Screen which shows information of refineries in a diagram & tabular view for more clarity
• Then comes the Main Dashboard screen, I divided the screen into graphical & tabular view making it more intuitive.
• Detailed Sensor View: Historical trends, filters, and comparison across multiple sensors.
• Comparison Screen: Graph + table combination for cross-plant or cross-component analysis.
All Plant
Oil Price
All plant location
All plant key metrics
Select plant
Plant Overview
Plant key metrics
all components
select component
Dashboard
Main screen
5 sensors
comparison options
Select Sensors
Sensor Data
Specific sensor insights
table + graph
compare graph
Comparison
compare 'N' sensors
table + graph
options
All Plant
• Oil Price
• All Plant Location
• All Plant key metrics
• Select Plant
Dashboard
• Main screen
• 5 Screens
• comparison options
• Select sensors
Plant Overview
• Plant key metrics
• All components
• Select component
Sensor Data
• Specific sensor
insights
• table + graph
• compare graph
Comparison
• Compare ‘N’ sensors
• table + graph
• options
User Flow
Before diving into the final design, I first mapped out the user flow to understand how a typical user would navigate the system and interact with different levels of information. The idea was to ensure clarity, reduce cognitive load, and apply progressive disclosure so that users see high-level insights first and can drill down into details only when needed.
Wireframes
Wireframes
Before moving into high-fidelity design, I created wireframes to validate the information architecture and layout. The goal here was to test how plant managers and technicians would interact with complex sensor data without getting overwhelmed. Wireframing allowed me to strip away visual noise and focus purely on hierarchy, navigation, and usability. I leveraged Miller’s Law, allowing users to process plant-level data as grouped, meaningful chunks instead of isolated values.
Low fidelity wireframe
layout & structure
Flare
Value
Insight
Gas Production
540 t
+5% from yesterday
Liquid Production
980 b/d
+11% from yesterday
Power Utilization
80%
+1.21% from yesterday
Map of Plant
Overview of all sensor data
Insights from historical trends
Current Sensor
Reading
Comparison from
other sensores
Graphical View
Tabulare View
Low fidelity wireframe
layout & structure
Flare
Value
Insight
Gas Production
540 t
+5% from yesterday
Liquid Production
980 b/d
+11% from yesterday
Power Utilization
80%
+1.21% from yesterday
Map of Plant
Overview of all sensor data
Insights from historical trends
Current Sensor
Reading
Comparison from
other sensores
Graphical View
Tabulare View
Low fidelity wireframe
layout & structure
Flare
Value
Insight
Gas Production
540 t
+5% from yesterday
Liquid Production
980 b/d
+11% from yesterday
Power Utilization
80%
+1.21% from yesterday
Map of Plant
Overview of all sensor data
Insights from historical trends
Current Sensor
Reading
Comparison from
other sensores
Graphical View
Tabulare View
Low fidelity wireframe
layout & structure
Flare
Value
Insight
Gas Production
540 t
+5% from yesterday
Liquid Production
980 b/d
+11% from yesterday
Power Utilization
80%
+1.21% from yesterday
Map of Plant
Overview of all sensor data
Insights from historical trends
Current Sensor
Reading
Comparison from
other sensores
Graphical View
Tabulare View
Final UI Design
Final UI Design
After iterating through research, user flows, and wireframes, the final design focused on delivering a clear, data-rich, yet intuitive dashboard that helps plant managers and technicians make quick, informed decisions.
Oil Price
84.56 $
+1.21$ updated last min
Flare
20 L
-20% from yesterday
Gas Production
540 t
+5% from yesterday
Liquid Production
980 b/d
+11% from yesterday
Power Utilization
80%
+1.21% from yesterday
Pump
Pump
Condenser
Condenser
Separator
Separator
Separator
Refinery
Refinery
Valve
Valve
Oil
Gas
Water
Liquid
Refinery_1
Refinery_2
Valve_1
Valve_2
Oil
Gas
Liquid
Pump_1
Pump_1
Separator_1
Separator_3
Separator_2
Condenser_1
Condenser_2
Utilization
80.7%
+2% from yesterday
Fuel Usage
375 L
+8% from yesterday
Tank Level
230 feet
+33% from yesterday
Choke Open Percentage
30%
-2% from yesterday
1,500 psi
Refinery Pressure
1,500 psi
Rx Pressure
1,300 psi
Gas Outlet Pressure
2,000 psi
Air Intel Pressure
2,000 psi
Pressure Refinery_1
Temperature Refinery_1
02:00PM
02:10PM
02:20PM
02:30PM
02:40PM
02:50PM
03:00PM
350°C
300°C
250°C
200°C
150°C
100°C
Feed Quality Control
API Gravity
32.3
Sulphur
0.803 wt%
Heavy Metals
2500 ppm
Initial Boiling
Point
220°C
Final Boiling
Point
750°C
Conradson Carbon
0.4 wt%
Characterization factor
10.07
Oil Flow Rate Refinery_1
Oil Inlet
3000m3/s
+4%
Oil Outlet
1500m3/s
-3%
Gas Outlet
1000m3/s
+2%
website.net
2104
+33%
Temperature Comparison
+2% Temperature from Refinery_2
Compare
Refinery_1
+2% Temperature from Refinery_2
-2% Flare Production from Refinery_2
-8% Conradson Carbon from Refinery_2
Temperature Refinery_1
148 °C
-2% from yesterday
Temperature
02:00PM
02:10PM
02:20PM
02:30PM
02:40PM
02:50PM
03:00PM
03:10PM
03:20PM
03:30PM
03:40PM
03:50PM
04:00PM
04:10PM
350°C
300°C
250°C
200°C
150°C
100°C
1W
24h
12h
6h
Today
Filters
Temperature
1W
24h
12h
6h
Today
Filters
02:00PM
02:10PM
02:20PM
02:30PM
02:40PM
02:50PM
03:00PM
03:10PM
03:20PM
03:30PM
03:40PM
03:50PM
04:00PM
04:10PM
350°C
300°C
250°C
200°C
150°C
100°C
Refinery_1 Texas Plant
Refinery_2 Texas Plant
Refinery_1 NYC Plant
Refinery_2 NYC Plant
+
Time
Refinery_1 Texas Plant
Temperature
Set Value
Refinery_2 Texas Plant
Temperature
Set Value
Refinery_1 NYC Plant
Temperature
Set Value
02:30 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
02:25 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
02:20 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
02:15 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
02:10 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
02:05 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
Oil Price
84.56 $
+1.21$ updated last min
Flare
20 L
-20% from yesterday
Gas Production
540 t
+5% from yesterday
Liquid Production
980 b/d
+11% from yesterday
Power Utilization
80%
+1.21% from yesterday
Pump
Pump
Condenser
Condenser
Separator
Separator
Separator
Refinery
Refinery
Valve
Valve
Oil
Gas
Water
Liquid
Refinery_1
Refinery_2
Valve_1
Valve_2
Oil
Gas
Liquid
Pump_1
Pump_1
Separator_1
Separator_3
Separator_2
Condenser_1
Condenser_2
Utilization
80.7%
+2% from yesterday
Fuel Usage
375 L
+8% from yesterday
Tank Level
230 feet
+33% from yesterday
Choke Open Percentage
30%
-2% from yesterday
1,500 psi
Refinery Pressure
1,500 psi
Rx Pressure
1,300 psi
Gas Outlet Pressure
2,000 psi
Air Intel Pressure
2,000 psi
Pressure Refinery_1
Temperature Refinery_1
02:00PM
02:10PM
02:20PM
02:30PM
02:40PM
02:50PM
03:00PM
350°C
300°C
250°C
200°C
150°C
100°C
Feed Quality Control
API Gravity
32.3
Sulphur
0.803 wt%
Heavy Metals
2500 ppm
Initial Boiling
Point
220°C
Final Boiling
Point
750°C
Conradson Carbon
0.4 wt%
Characterization factor
10.07
Oil Flow Rate Refinery_1
Oil Inlet
3000m3/s
+4%
Oil Outlet
1500m3/s
-3%
Gas Outlet
1000m3/s
+2%
website.net
2104
+33%
Temperature Comparison
+2% Temperature from Refinery_2
Compare
Refinery_1
+2% Temperature from Refinery_2
-2% Flare Production from Refinery_2
-8% Conradson Carbon from Refinery_2
Temperature Refinery_1
148 °C
-2% from yesterday
Temperature
02:00PM
02:10PM
02:20PM
02:30PM
02:40PM
02:50PM
03:00PM
03:10PM
03:20PM
03:30PM
03:40PM
03:50PM
04:00PM
04:10PM
350°C
300°C
250°C
200°C
150°C
100°C
1W
24h
12h
6h
Today
Filters
Temperature
1W
24h
12h
6h
Today
Filters
02:00PM
02:10PM
02:20PM
02:30PM
02:40PM
02:50PM
03:00PM
03:10PM
03:20PM
03:30PM
03:40PM
03:50PM
04:00PM
04:10PM
350°C
300°C
250°C
200°C
150°C
100°C
Refinery_1 Texas Plant
Refinery_2 Texas Plant
Refinery_1 NYC Plant
Refinery_2 NYC Plant
+
Time
Refinery_1 Texas Plant
Temperature
Set Value
Refinery_2 Texas Plant
Temperature
Set Value
Refinery_1 NYC Plant
Temperature
Set Value
02:30 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
02:25 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
02:20 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
02:15 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
02:10 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
02:05 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
Oil Price
84.56 $
+1.21$ updated last min
Flare
20 L
-20% from yesterday
Gas Production
540 t
+5% from yesterday
Liquid Production
980 b/d
+11% from yesterday
Power Utilization
80%
+1.21% from yesterday
Pump
Pump
Condenser
Condenser
Separator
Separator
Separator
Refinery
Refinery
Valve
Valve
Oil
Gas
Water
Liquid
Refinery_1
Refinery_2
Valve_1
Valve_2
Oil
Gas
Liquid
Pump_1
Pump_1
Separator_1
Separator_3
Separator_2
Condenser_1
Condenser_2
Utilization
80.7%
+2% from yesterday
Fuel Usage
375 L
+8% from yesterday
Tank Level
230 feet
+33% from yesterday
Choke Open Percentage
30%
-2% from yesterday
1,500 psi
Refinery Pressure
1,500 psi
Rx Pressure
1,300 psi
Gas Outlet Pressure
2,000 psi
Air Intel Pressure
2,000 psi
Pressure Refinery_1
Temperature Refinery_1
02:00PM
02:10PM
02:20PM
02:30PM
02:40PM
02:50PM
03:00PM
350°C
300°C
250°C
200°C
150°C
100°C
Feed Quality Control
API Gravity
32.3
Sulphur
0.803 wt%
Heavy Metals
2500 ppm
Initial Boiling
Point
220°C
Final Boiling
Point
750°C
Conradson Carbon
0.4 wt%
Characterization factor
10.07
Oil Flow Rate Refinery_1
Oil Inlet
3000m3/s
+4%
Oil Outlet
1500m3/s
-3%
Gas Outlet
1000m3/s
+2%
website.net
2104
+33%
Temperature Comparison
+2% Temperature from Refinery_2
Compare
Refinery_1
+2% Temperature from Refinery_2
-2% Flare Production from Refinery_2
-8% Conradson Carbon from Refinery_2
Temperature Refinery_1
148 °C
-2% from yesterday
Temperature
02:00PM
02:10PM
02:20PM
02:30PM
02:40PM
02:50PM
03:00PM
03:10PM
03:20PM
03:30PM
03:40PM
03:50PM
04:00PM
04:10PM
350°C
300°C
250°C
200°C
150°C
100°C
1W
24h
12h
6h
Today
Filters
Temperature
1W
24h
12h
6h
Today
Filters
02:00PM
02:10PM
02:20PM
02:30PM
02:40PM
02:50PM
03:00PM
03:10PM
03:20PM
03:30PM
03:40PM
03:50PM
04:00PM
04:10PM
350°C
300°C
250°C
200°C
150°C
100°C
Refinery_1 Texas Plant
Refinery_2 Texas Plant
Refinery_1 NYC Plant
Refinery_2 NYC Plant
+
Time
Refinery_1 Texas Plant
Temperature
Set Value
Refinery_2 Texas Plant
Temperature
Set Value
Refinery_1 NYC Plant
Temperature
Set Value
02:30 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
02:25 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
02:20 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
02:15 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
02:10 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
02:05 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
Oil Price
84.56 $
+1.21$ updated last min
Flare
20 L
-20% from yesterday
Gas Production
540 t
+5% from yesterday
Liquid Production
980 b/d
+11% from yesterday
Power Utilization
80%
+1.21% from yesterday
Pump
Pump
Condenser
Condenser
Separator
Separator
Separator
Refinery
Refinery
Valve
Valve
Oil
Gas
Water
Liquid
Refinery_1
Refinery_2
Valve_1
Valve_2
Oil
Gas
Liquid
Pump_1
Pump_1
Separator_1
Separator_3
Separator_2
Condenser_1
Condenser_2
Utilization
80.7%
+2% from yesterday
Fuel Usage
375 L
+8% from yesterday
Tank Level
230 feet
+33% from yesterday
Choke Open Percentage
30%
-2% from yesterday
1,500 psi
Refinery Pressure
1,500 psi
Rx Pressure
1,300 psi
Gas Outlet Pressure
2,000 psi
Air Intel Pressure
2,000 psi
Pressure Refinery_1
Temperature Refinery_1
02:00PM
02:10PM
02:20PM
02:30PM
02:40PM
02:50PM
03:00PM
350°C
300°C
250°C
200°C
150°C
100°C
Feed Quality Control
API Gravity
32.3
Sulphur
0.803 wt%
Heavy Metals
2500 ppm
Initial Boiling
Point
220°C
Final Boiling
Point
750°C
Conradson Carbon
0.4 wt%
Characterization factor
10.07
Oil Flow Rate Refinery_1
Oil Inlet
3000m3/s
+4%
Oil Outlet
1500m3/s
-3%
Gas Outlet
1000m3/s
+2%
website.net
2104
+33%
Temperature Comparison
+2% Temperature from Refinery_2
Compare
Refinery_1
+2% Temperature from Refinery_2
-2% Flare Production from Refinery_2
-8% Conradson Carbon from Refinery_2
Temperature Refinery_1
148 °C
-2% from yesterday
Temperature
02:00PM
02:10PM
02:20PM
02:30PM
02:40PM
02:50PM
03:00PM
03:10PM
03:20PM
03:30PM
03:40PM
03:50PM
04:00PM
04:10PM
350°C
300°C
250°C
200°C
150°C
100°C
1W
24h
12h
6h
Today
Filters
Temperature
1W
24h
12h
6h
Today
Filters
02:00PM
02:10PM
02:20PM
02:30PM
02:40PM
02:50PM
03:00PM
03:10PM
03:20PM
03:30PM
03:40PM
03:50PM
04:00PM
04:10PM
350°C
300°C
250°C
200°C
150°C
100°C
Refinery_1 Texas Plant
Refinery_2 Texas Plant
Refinery_1 NYC Plant
Refinery_2 NYC Plant
+
Time
Refinery_1 Texas Plant
Temperature
Set Value
Refinery_2 Texas Plant
Temperature
Set Value
Refinery_1 NYC Plant
Temperature
Set Value
02:30 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
02:25 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
02:20 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
02:15 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
02:10 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
02:05 PM
250°C
1800°C
250°C
250°C
250°C
1800°C
1800°C
Plant Monitoring system
Learnings & Conclusion
Importance of Problem Definition: Early on, I got lost in too much research. Breaking the problem into smaller, well-defined goals helped me focus and made the design more purposeful and effective.
UX is More Than Tools: UX goes beyond creating screens in Figma. It’s about understanding user needs, conducting meaningful research, iterating thoughtfully, and crafting experiences that truly solve problems.
Feedback is Fuel: When I started my UX journey, I use to love my design and took feedback as a bullet but with time I learned and now I take feedback positively and implemented it.
Importance of Problem Definition: Early on, I got lost in too much research. Breaking the problem into smaller, well-defined goals helped me focus and made the design more purposeful and effective.
UX is More Than Tools: UX goes beyond creating screens in Figma. It’s about understanding user needs, conducting meaningful research, iterating thoughtfully, and crafting experiences that truly solve problems.
Feedback is Fuel: When I started my UX journey, I use to love my design and took feedback as a bullet but with time I learned and now I take feedback positively and implemented it.