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.
In this webinar, Hilcorp and Rockwell Automation share a real-world case study of how a major Alaskan production facility successfully executed a live “hot cutover” from a legacy PLC‑5 control system to a modern ControlLogix platform, without shutting down operations.
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, Hilcorp and 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:
Troy Johnson
Automation & Controls Engineering Manager
Hilcorp
Troy Johnson is a seasoned industrial automation leader with over three decades of experience delivering complex instrumentation and control projects in high-risk energy environments, including 15 years on the Alaskan North Slope. As a Registered Professional Engineer (P.E.) with an MBA, he brings a rare blend of technical depth and financial acumen—guiding multidisciplinary teams from FEED through commissioning while managing multi-million dollar capital and O&M portfolios.
He specializes in DCS, SCADA, and PLC system integration, operational resilience through OT cybersecurity and process safety, and translating real-time data into actionable business insights. A strong advocate for ethical leadership, Troy is equally committed to mentoring the next generation of engineers and advancing safety and performance standards across the industry.
Russel Krug
OT Systems Administrator
Hilcorp
