Modern SCADA System Upgrade Transforms Petroleum Operations

Legacy System Challenges in Petroleum Industry

Heritage Petroleum Company inherited outdated SCADA infrastructure after reorganization. The system required immediate modernization for efficient operations. According to MarketsandMarkets, the SCADA market will reach $56 billion by 2028. Digital transformation became essential for competitive operations.

Strategic Two-Phase Implementation Approach

The upgrade followed a carefully structured implementation plan:

• Phase 1 focused on SCADA system core upgrades
• Phase 2 integrated remote sensor monitoring capabilities
• TOSL Automation managed project execution
• International partners provided specialized expertise

This approach ensured systematic technology transformation.

SCADA System Modernization Strategy

The team implemented cost-effective upgrade solutions:

• Upgraded existing AVEVA InTouch and Historian systems
• Preserved functional hardware infrastructure components
• Integrated Web Client for enhanced accessibility
• Connected data streams to enterprise ERP systems

This strategy saved significant time and resources.

Advanced MQTT Integration for Remote Monitoring

The project incorporated modern IoT communication protocols:

• Skkynet DataHub served as Smart MQTT Broker
• Integrated HiberHilo LoRaWAN sensor networks
• Enabled direct SCADA system data ingestion
• Supported future system expansion requirements

This integration enabled comprehensive remote monitoring.

Complex Data Processing and Protocol Conversion

The team addressed significant technical challenges:

• Processed multiple JSON data formats from various sensors
• Developed custom scripts for data normalization
• Created meaningful tag structures in InTouch
• Built customized visualization screens from scratch

These solutions ensured usable data presentation.

Redundant System Architecture Implementation

The project incorporated robust reliability features:

• Dual MQTT server configuration for redundancy
• Quality-of-service monitoring for data paths
• Automatic failover between server connections
• Continuous data connectivity preservation

This architecture ensured operational reliability.

Control System Integration and Benefits

The upgraded system delivered significant improvements:

• Enhanced integration with PLC and DCS systems
• Improved analytics and alarm management capabilities
• Better third-party application connectivity
• Increased system scalability for future expansion

These benefits transformed operational visibility.

Expert Analysis: Industrial Automation Evolution

From PLCDCSHUB’s perspective, this case demonstrates key trends:

• Legacy system modernization preserves existing investments
• MQTT protocol becomes standard for industrial IoT
• Hybrid cloud-edge architectures gain popularity
• Custom scripting enables unique integration requirements

These developments shape modern factory automation approaches.

Implementation Best Practices and Lessons

The project revealed important implementation insights:

• Thorough system assessment prevents unnecessary replacements
• International partnerships provide specialized expertise
• Custom scripting addresses unique protocol requirements
• Comprehensive training ensures long-term system management

These practices ensure successful automation projects.

Future Expansion and Scalability Planning

Heritage Petroleum plans continued system enhancement:

• Onshore business unit integration projects
• Additional sensor deployment and monitoring
• Enhanced InTouch visualization screens
• Further DataHub installation expansion

This planning supports ongoing digital transformation.

Connecting SCADA Modernization to Operational Excellence

Modern industrial automation requires integrated solutions. For comprehensive control system expertise, PLCDCSHUB provides industrial automation knowledge and components. Our platform supports digital transformation initiatives.

Frequently Asked Questions

• What were the main cost savings from this approach?
• Reusing existing infrastructure saved approximately six months of implementation time and associated costs.
• How does MQTT benefit industrial automation systems?
• It provides lightweight, efficient communication perfect for remote sensors and IoT devices in harsh environments.
• What technical support was most valuable during implementation?
• Custom script development and rapid troubleshooting support ensured project success within tight timelines.