The Challenge: Legacy System Overload

Our client, a major refinery in Alberta, was struggling with a 15-year-old SCADA interface that was causing critical operational bottlenecks. The legacy system presented data across dozens of non-standardized screens, forcing control room operators to perform excessive navigation and mental mapping during high-stakes procedures. This led to increased cognitive load, delayed response times to alarms, and a concerning near-miss incident during a pressure surge event.

The primary objective was not just a visual refresh, but a complete overhaul of information architecture to prioritize safety-critical parameters and streamline standard operating procedures (SOPs).

Our Human-Centered Solution

We deployed a user-centered design process, beginning with a two-week ethnographic study inside the control room. We shadowed operators across all shifts, mapping their workflows, pain points, and decision-making pathways under normal and emergency conditions.

The solution was a modular, tile-based HMI dashboard built on a real-time data engine. We introduced a persistent "Safety Horizon" bar at the top of every screen, displaying live values for pressure, temperature, and flow rates for the unit in focus, with color-coded thresholds. The core interface was reorganized into three contextual zones:

• Zone 1 - Immediate Awareness: Persistent safety and key performance indicators (KPIs).
• Zone 2 - Active Control: Interactive controls and detailed schematics for the active process unit.
• Zone 3 - Context & History: Trend graphs, alarm logs, and procedural checklists relevant to the current task.

Technical Implementation & Process

The development followed an agile, iterative model with weekly feedback sessions from a pilot group of operators. The frontend was built using a modern JavaScript framework for high-performance rendering of real-time data streams, while the backend integrated securely with the refinery's existing OPC UA servers.

A key innovation was the "Procedural Guidance Module." Instead of static PDF checklists, we embedded interactive SOPs directly into the interface. As an operator completes a step, such as "Open Valve XV-102," the system can highlight the corresponding element on the P&ID schematic and log the action automatically.

• Phase 1: Discovery & User Research (3 weeks)
• Phase 2: Information Architecture & Wireframing (2 weeks)
• Phase 3: High-Fidelity Prototyping & Usability Testing (4 weeks)
• Phase 4: Development & Integration (10 weeks)
• Phase 5: Phased Rollout & Training (3 weeks)

Measurable Results & Impact

Post-implementation metrics, collected over six months, demonstrated significant improvements in operational ergonomics and safety.

• 38% Reduction in average alarm response time.
• 72% Fewer screen navigation actions per shift, as reported by the system logs.
• 94% Operator Satisfaction with the new interface's clarity, based on post-rollout surveys.
• Elimination of manual SOP logging, saving an estimated 45 minutes per operator per day.
• The client reported a measurable decrease in procedural deviations during complex unit startups.