Migration and Reverse Engineering Project Case Study

• Preparation of System Architecture
• Preparation of IO lists as per running PLC backup.
• C&E validation with running PLC backups.
• P&ID’s validation with running PLC backup.
• Control Narrative validation with running PLC backup.
• Loop drawings & wiring drawing’s validation.
• Installation and Operation manual review.
• Flow chart drawing validation with running PLC backups.
• Functional logic diagram preparation as per running PLC backup.
• Packages PLC logic validation report preparation for 39 controllers
• FGS logic validation report Preparation for 35 Controllers.
• LV summary report testing with AGP Site
• FEED Document preparation for all ESD and FGS controllers
• All existing documents marked up as per changes.
• Approx. 16000 IO’s

Advanced Automation Solutions for the Oil & Gas Industry

The oil and gas sector operates in a demanding environment, requiring precision, safety and unwavering reliability. At iPAC Automation, we understand these critical needs. We provide comprehensive automation solutionsdesigned to optimize your operations, enhance efficiency and ensure the highest safety standards across the entire oil and gas value chain.

From upstream exploration and production to midstream transportation and storage and downstream refining and distribution, our expertise spans the full spectrum of the industry. We leverage cutting-edge technologies and proven methodologies to deliver solutions that address your specific challenges and drive tangible results.

Our Automation Expertise in Oil & Gas:

• Process Automation: We design and implement Distributed Control Systems (DCS), Programmable Logic Controllers (PLC)and Supervisory Control and Data Acquisition (SCADA) systemsto automate and control critical processes. This includes wellhead control, pipeline management, refinery unit control and terminal automation. Our solutions ensure precise control, reduce manual intervention and improve overall process efficiency.
• Safety Systems: Safety is paramount in the oil and gas industry. We develop and integrate robust safety instrumented systems (SIS), including Emergency Shutdown (ESD) systems, Fire and Gas (F&G) detection systems and High-Integrity Pressure Protection Systems (HIPPS). Our SIL-rated solutions are designed to mitigate risks, protect personnel and assets and comply with stringent safety regulations.
• Asset Management: Optimizing asset performance and minimizing downtime are crucial for profitability. We implement asset management solutions that provide real-time visibility into equipment health, enabling predictive maintenance, reducing unplanned outages and extending asset lifespan. This includes condition monitoring systems and integrated asset management platforms.
• Terminal Automation: Efficient management of oil and gas terminals is essential for smooth logistics and operations. Our terminal automation systems streamline loading and unloading processes, tank farm management, inventory control and custody transfer, improving throughput and accuracy.
• Pipeline Automation: Ensuring the safe and efficient transportation of hydrocarbons through pipelines requires sophisticated automation. We provide solutions for pipeline monitoring, leak detection systems, compressor station control and flow management, enhancing pipeline integrity and operational efficiency.
• Data Acquisition and Historian Systems: Access to accurate and timely data is vital for informed decision-making. We implement data acquisition systems and industrial historians that collect, store and analyze critical operational data, providing valuable insights for optimization and performance improvement.

Why Partner with iPAC Automation for Your Oil & Gas Needs?

• Deep Industry Knowledge: Our team possesses extensive experience and a thorough understanding of the unique challenges and complexities of the oil and gas sector.
• Technological Excellence: We stay at the forefront of automation technologies, offering innovative and reliable solutions tailored to your specific requirements.
• Safety-First Approach: Safety is ingrained in our culture and our solutions are designed with the highest safety standards in mind.
• End-to-End Solutions: From initial consultation and design to implementation, commissioning and ongoing support, we provide comprehensive services throughout the project lifecycle.
• Commitment to Performance: We are dedicated to delivering solutions that improve your operational efficiency, reduce costs and enhance your bottom line.

Effortless Migration and Expert Reverse Engineering for Oil & Gas Automation Systems

As automation systems in the oil and gas industry age, businesses face the critical challenge of modernization without disrupting ongoing operations. AtiPAC Automation, we offer specialized migration and reverse engineering services to help you seamlessly transition to newer technologies and gain a deeper understanding of your existing infrastructure.

Smooth and Efficient Migration Services:

Upgrading legacy automation systems can be complex and carry significant risks. Our experienced team employs a structured and meticulous approach to ensure a smooth and efficient migration process. We understand the criticality of minimizing downtime and preserving operational integrity during these transitions.

Our migration services encompass:

• Detailed System Assessment: We conduct thorough evaluations of your existing automation systems, including control systems (DCS, PLC, SCADA), safety systems (ESD, F&G) and communication networks, to understand their architecture, functionality and limitations.
• Comprehensive Migration Planning: Based on the assessment, we develop a detailed migration plan that outlines the scope of work, timelines, resource requirements and risk mitigation strategies. We work closely with your team to ensure the plan aligns with your operational needs and constraints.
• Technology Upgrade and Replacement: We have expertise in migrating to the latest automation platforms and technologies, ensuring compatibility, enhanced performance and future scalability. This includes hardware and software upgrades, control system replacements and network modernization.
• Data Migration and Validation: We ensure the seamless transfer of critical process data and configurations from your legacy systems to the new platform, with rigorous validation to maintain data integrity.
• Testing and Commissioning: Our thorough testing and commissioning procedures ensure that the migrated system functions correctly and meets all performance requirements before going live.
• Post-Migration Support: We provide ongoing support and maintenance to ensure the continued reliability and optimal performance of your newly migrated automation system.

Expert Reverse Engineering Services:

Understanding the intricacies of your existing automation systems is crucial for effective maintenance, upgrades and troubleshooting, especially when documentation is outdated or unavailable. Our reverse engineering services provide you with valuable insights into your operational infrastructure.

Our reverse engineering capabilities include:

• Control System Analysis: We analyze the configuration and logic of your existingDCS, PLC and SCADAsystems to create accurate functional specifications and control narratives.
• Network Mapping: We map out your industrial communication networks, identifying protocols, devices and data flow to understand the system’s architecture and potential points of failure.
• Hardware and Software Documentation: We can recreate or update documentation for your automation hardware and software components, providing you with accurate and up-to-date records.
• Identification of Obsolescence Risks: We assess your current systems to identify components that are nearing obsolescence, allowing for proactive planning and mitigation strategies.
• Generating As-Built Drawings and Schematics: We can create or update electrical drawings, loop diagrams and system architecture diagrams to provide a clear understanding of your physical and logical infrastructure.

Benefits of Our Migration and Reverse Engineering Services:

• Reduced Downtime: Our structured approach minimizes disruption to your operations during migration projects.
• Minimized Risks: Thorough planning and testing mitigate the risks associated with system upgrades.
• Improved System Performance: Modernized systems offer enhanced functionality, performance and security.
• Enhanced Understanding of Existing Systems: Reverse engineering provides valuable insights for better maintenance and troubleshooting.
• Cost-Effective Modernization: Strategic migration can be a more cost-effective alternative to a complete system replacement.

Looking to modernize your automation systems or gain a deeper understanding of your existing infrastructure? Contact us!