Upgrading Legacy Automation in Live Oil & Gas Operations
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Modernizing aging control systems without disrupting production is one of the most complex challenges facing oil and gas operators, especially in mature, high-output facilities where uptime, safety, and performance are non-negotiable.
Supporting a central production hub handling oil, gas, and water with ~50,000 BOPD capacity, the project required careful coordination to maintain process continuity across critical systems including artificial lift, gas compression, and water reinjection.
Attendees will gain an inside look at the structured approach that enabled success, from early site inspections and a comprehensive Front-End Engineering Design (FEED) that defined architecture and cutover strategy, to rigorous testing (HAT, FAT, SAT) and full lab staging that minimized execution risk.
The session will highlight how parallel system operation, a purpose-built data concentrator, and a master I/O framework enabled a phased, controlled migration, ensured continuous safety system integrity, uninterrupted operator visibility, and seamless transition between legacy and modern systems.
Beyond execution, Rockwell will also share key success factors and lessons learned. Key takeaways include:
- How to design and execute a zero-downtime PLC migration in a live production environment
- Strategies to maintain safety, operator continuity, and system integrity during transition
- The role of FEED, simulation, and staging in de-risking complex automation upgrades
- Lessons learned to improve future large-scale migrations
Join this session to learn how disciplined engineering, strong collaboration, and innovative architecture can unlock modernization, without compromising production.
Speakers:
Marco Zarco Cardenas
Project Engineer
Rockwell Automation
Don Violi
Project Manager
Rockwell Automation
Don Violi has over 20 years’ experience in the Process Automation/Process Safety industry in a variety of roles. My background includes Manufacturing, Project Engineering, and both Project and Program Management. I specialize in delivering complex Oil & Gas project involving integrated electrical and control systems.
Paul Miranda
Global Account Manager
Rockwell Automation
Paul Miranda is an accomplished energy industry professional with extensive experience spanning engineering, operations, capital projects, and business development. He began his career with ConocoPhillips as an Instrumentation and Controls Engineer, where he supported both operational facilities and major capital projects, gaining deep expertise in process automation, control systems, instrumentation, and project execution within the oil and gas sector.
Building on this strong technical foundation, Paul transitioned into commercial leadership roles and has spent the last 10 years serving as a Business Development Manager and Global Account Manager. In these positions, he has worked closely with leading energy companies to develop strategic partnerships, drive business growth, and deliver technology and operational solutions that improve efficiency, reliability, and business performance.
Combining hands-on engineering experience with a decade of customer-facing leadership, Paul brings a unique perspective on the intersection of technology, operations, and business strategy in the evolving energy landscape.
