This Consolidation Project was a large-scale, decade-long initiative aimed at consolidating four legacy SCADA systems into two primary platforms: Weatherford CygNet and AVEVA Enterprise SCADA (OASyS). This project spanned over 10 years and involved multiple phases of integration, design, commissioning, and operational support, making it one of the largest SCADA consolidation efforts in the oil and gas industry.
Scope and Complexity
The scope of the project was vast, covering the entirety of the client’s natural gas pipeline operations, which span across North America. Our task was to migrate and integrate data from four disparate SCADA systems into two streamlined platforms, ensuring minimal disruption to daily operations and maintaining high system availability throughout the transition. This included:
- Data Migration and System Integration: Migrating real-time data and historical records from the legacy SCADA systems was a critical part of the project. We handled this complex task with careful planning, ensuring data integrity and synchronization across the newly consolidated platforms. Integration of third-party systems was also essential to align with the client’s operational and business goals.
- High-performance HMI Development : We developed SCADA displays in compliance with API 1165 standards, focusing on operator efficiency and situational awareness. These displays were designed to minimize unnecessary visual elements while emphasizing critical data, allowing operators to manage pipelines effectively and make swift, informed decisions.
- Full Point-to-Point Commissioning: As part of the commissioning process, our team provided point-to-point testing and verification of all systems, ensuring that every data point and control element functioned 33 as expected. This was crucial for the successful operation of pipeline controls, leak detection, and overall system reliability.
- Team Expertise and Training: To support the client’slong-term operational goals, we deployed SCADA SMEs, engineers, and display developers with extensive experience in Weatherford CygNet and AVEVA Enterprise SCADA. Our experts worked alongside the client’s teams to design, implement, and test the new system configurations. We also delivered comprehensive training to the client’s pipeline controllers and SCADA operators, equipping them with the skills needed to effectively use and maintain the new system.
- Challenges and Solutions: One of the major challenges was managing the scale and complexity of the consolidation without causing downtime or operational risk. Given the importance of the client’s infrastructure, any disruption could have had significant financial and safety consequences. We tackled this by using a phased approach, deploying redundant systems and ensuring robust contingency plans were in place. Additionally, our expertise in both Weatherford CygNet and AVEVA OASyS allowed us to execute a seamless integration across different operational environments.
Outcomes and Benefits
The new consolidated SCADA system provided the client’s with:
- Enhanced monitoring and control across its pipeline network, allowing for more efficient operations and improved safety measures.
- Operational cost savings through the decommissioning of redundant systems and a streamlined maintenance process.
- A future-proof solution, with scalability options built in, allowing for easy integration of new assets and technologies in the years to come.
Conclusion
In conclusion, this Consolidation Project represents a monumental achievement in the oil and gas industry’s evolution toward modernized SCADA solutions. Over the course of a decade, we successfully integrated four legacy systems into two robust platforms—Weatherford CygNet and AVEVA Enterprise SCADA—streamlining operations across the client’s extensive natural gas pipeline network.
This project not only addressed the complexities of data migration and system integration but also prioritized the safety and efficiency of daily operations through the development of high-performance HMI displays and rigorous point-to-point commissioning. Our collaborative efforts with the client’s teams ensured that the transition was implemented smoothly, without interrupting critical operations, while our focus on training empowered their personnel to manage and maintain the new systems effectively.
The outcomes of this ambitious initiative have been significant: enhanced monitoring and control, operational cost reductions, and a scalable infrastructure positioned for future growth and technological advancements. As we look to the future, we are proud to have contributed to the client’s continued success and are excited about the lasting impact this project will have on their operations. This consolidation not only simplifies processes but also sets a strong foundation for innovation and efficiency in years to come.