With over two decades of expertise in SCADA systems, Industry 4.0 technologies, and automation engineering, I have spearheaded transformative projects that drive operational efficiency, digital innovation, and seamless integration across industries. My professional journey reflects a commitment to delivering tailored solutions that address complex challenges, leveraging cutting-edge technologies to empower organizations in sectors such as energy, manufacturing, and industrial automation.
Below is a curated selection of high-level projects from my portfolio, illustrating my expertise in digital transformation, custom software development, and innovative engineering solutions. Each project highlights a unique approach to solving industry-specific challenges, fostering growth, and setting benchmarks in operational excellence.
2018 – 2024 Notable Projects
Generative AI Platform
Technological Highlights
DevOps Tools: Azure DevOps, npm/yarn pipelines
Frontend Frameworks: Svelte, Electron
Cloud Services: Cloudflare (Workers, R2, Zero Trust, KV Storage), Supabase, Microsoft Azure
AI Integrations: OpenAI, Claude, Groq APIs
Security: Zero Trust Network Access (ZTNA), mTLS encryption, conditional access policies
This project focused on the design and implementation of a cutting-edge generative AI platform for BloomBox. I played a key role in both the frontend and backend development, as well as in architecting a robust and scalable cloud infrastructure. Leveraging Industry 4.0 principles and modern technologies, this platform integrates seamlessly with Cloudflare, Supabase, and Microsoft Azure for enhanced performance, security, and scalability.
Core Contributions
1. Frontend Development:
- Designed and developed an intuitive user interface using Svelte and Electron, ensuring seamless interaction with the generative AI platform.
- Created real-time data visualization tools and dashboards, enhancing user engagement and operational efficiency.
2. Backend Development:
- Built and optimized the backend using Cloudflare Workers APIs to ensure secure, low-latency data processing and API management.
- Developed API endpoints for real-time interactions with AI services and external APIs such as OpenAI, Groq, and Claude.
3. Cloud Architecture Design:
- Architected a Zero Trust Network Infrastructure using Cloudflare Zero Trust for enhanced security and seamless authentication across user devices.
- Implemented end-to-end encryption using mTLS for secure data transmission, adhering to Zero Trust principles.
- Designed a fault-tolerant system using durable objects, KV storage, and R2 storage to ensure high availability and data redundancy.
4. Integration with External Services:
- Integrated Supabase for database management and authentication, ensuring robust user management and data security.
- Deployed AI services in a region-specific manner to optimize latency and comply with data residency requirements.
5. DevOps & Pipeline Setup:
- Configured Azure DevOps for version control, continuous integration/continuous deployment (CI/CD), and sprint-driven project management.
- Designed build pipelines with npm/yarn for seamless deployment.
Impact
- Delivered a scalable, secure generative AI platform that streamlined data handling, enhanced user experience, and ensured enterprise-grade security.
- Achieved fault tolerance and high availability, enabling uninterrupted access for global users.
- Empowered BloomBox to provide cutting-edge generative AI solutions, strengthening its position in the market.
Client Information
Client Name: Bloombox Distribution
Location: Oklahoma City, Oklahoma
Year: 2024
Midstream Enterprise SCADA System
Technological Highlights
SCADA Platform: Ignition Master Gateway, Ignition Cloud Gateway, Ignition Edge Gateway.
RTU Integration: ABB Totalflow RTU drivers.
Scripting Tools: Python for custom scripting and JSON-based tag management.
PLC: Allen-Bradley ControlLogix (post-PlantPAx removal).
Designed, developed, and implemented a comprehensive Ignition SCADA system for Northwind Midstream’s enterprise operations. This multi-phase project enhanced real-time monitoring and control across 40 remote locations, ensuring scalability, reliability, and streamlined processes.
Core Contributions
SCADA Architecture:
- Designed and configured an on-premises Ignition Master Gateway for centralized data acquisition and control.
- Developed and implemented a Cloud Ignition Gateway to enable remote access and redundancy.
- Configured Ignition Edge Gateways for 40 remote locations, ensuring seamless communication and data synchronization.
Screen Development:
- Developed process screens for Project Phases 1, 1.5, and 2 to accommodate new equipment installations and process expansions.
- Migrated standard Ignition/PlantPAx screens and faceplates to a new templated approach post-removal of the PlantPAx Process Control System.
Custom Scripting and Tag Management:
- Created a custom JSON-based tag structure and application to streamline tag imports into the Ignition Master Gateway.
- Configured tag structures based on Engineering I/O Lists and P&ID Drawings for accurate system integration.
Driver and Device Configuration:
- Set up and configured ABB Totalflow Ignition Drivers for all RTUs at remote locations, ensuring seamless data collection.
Support and Commissioning:
- Provided remote support to operations control rooms and field personnel for resolving Gateway, Vision Client, tag, and communication issues.
- Supported the startup and commissioning of new process phases.
- Addressed support requests through Microsoft Teams for efficient collaboration.
Impact
This project successfully delivered a robust, scalable SCADA system, improving operational efficiency and enhancing real-time data visibility across Northwind Midstream’s enterprise. The templated approach for screen migration and advanced tag management streamlined processes, while remote support ensured uninterrupted operations during critical project phases.
Client Information
Client Name: Colexas Digital | Northwind Midstream
Location: Houston, Texas
Year: 2024
OASys 7.5 to Aveva Enterprise 2024 SCADA System Upgrade
Technological Highlights
SCADA Platforms: OASys 7.5, Aveva Enterprise 2024.
Development Tools: Visual Studio C#.NET.
HMI Development: Migrated and modernized screens for Aveva Enterprise.
Database and Integration: Supported backend changes for integration with new Aveva systems.
This project involved upgrading Colonial Pipeline’s existing OASys 7.5 SCADA system to Aveva Enterprise 2024, requiring extensive code analysis, application development, and system integration. The work ensured a seamless migration while maintaining critical functionality and modernizing the SCADA environment.
Core Contributions
Code Analysis and Application Development:
- Conducted in-depth analysis and developed solutions for legacy applications using C#.NET:
- Remote Meter Proving Application: Refined and optimized functionality for precise flow measurement validation.
- Remote Batch Monitoring Application: Enhanced application features to improve remote batch data tracking and monitoring.
- CUI Tank Test Application: Streamlined tank testing procedures with modernized code for accuracy and reliability.
- JSH Permissive Application: Re-engineered permissive logic to meet current operational requirements.
Documentation and Reporting:
- Developed detailed documentation and comprehensive reports for all code analysis and solution design, providing a clear path for future system enhancements and maintenance.
HMI Screen Migration and Solution Path:
- Performed in-depth analysis of existing OASys 7.5 HMI screens, identifying challenges and defining a migration path to Aveva Enterprise 2024.
- Developed and tested new HMI screens aligned with the Aveva Enterprise architecture.
Custom Integration for Aveva Enterprise 2024:
- Designed and implemented custom C#.NET applications to integrate seamlessly with Aveva Enterprise 2024.
- Addressed the lack of Daemon Mode in Aveva Enterprise 2024 by reconfiguring application workflows to ensure compatibility and uninterrupted operation.
Impact
This project ensured a successful upgrade of Colonial Pipeline’s SCADA system to Aveva Enterprise 2024, preserving critical application functionalities and providing enhanced system reliability. The integration of custom solutions addressed platform limitations, ensuring a smooth transition and improved operational efficiency.
Client Information
Client Name: Berkana Resources | Colonial Pipeline
Location: Atlanta, Georgia
Year: 2024
Mobile Broadband & Weather Station System
Technological Highlights
Power Systems: Solar-powered energy systems.
Edge Computing: Edge Computer and UX design for local processing.
Cloud Platform: Microsoft Azure IoT Hub and Dashboard.
Communication: Starlink APIs, 900 MHz Spread Spectrum Radio Networks.
Development Tools: Microsoft Azure DevOps for project and code management.
Designed and implemented a comprehensive solution for a solar-powered Mobile Broadband and Weather Station System. This project integrated advanced communication technologies, edge computing, and cloud-based monitoring to provide reliable data collection and analysis.
Core Contributions
System Design and Integration:
- Developed a solar-powered control system to ensure autonomous operation in remote locations.
- Designed the Edge Computer and Edge User Experience (UX) to facilitate real-time data processing and user interaction.
- Integrated with Microsoft IoT for seamless connectivity and data synchronization.
Cloud and Dashboard Development:
- Created a user-friendly Microsoft Azure Dashboard UX, enabling real-time visualization and analysis of weather and broadband data.
- Leveraged Azure cloud capabilities to store, process, and manage data effectively.
API Development for Communication Networks:
- Built custom APIs to interface with Starlink for satellite-based internet connectivity and 900 MHz Spread Spectrum Radio Networks for robust communication in remote areas.
Project Management Setup:
- Configured Microsoft Azure DevOps for streamlined sprint-driven project management.
- Enabled collaborative source code tracking and efficient test plan management for all system components.
Impact
The project successfully delivered a fully operational Mobile Broadband and Weather Station System, ensuring reliable data collection and connectivity in remote locations. The integration of cutting-edge technologies improved operational efficiency, enabled real-time monitoring, and provided scalable solutions for future deployments.
Client Information
Client Name: Washington State University | Microsoft | SpaceX
Location: Republic, Washington
Year: 2022–2023
Fault Tolerant Kubernetes & Node-Red Solution
Technological Highlights
Orchestration: Kubernetes Services Architecture.
Flow-Based Programming: Node-Red for redundancy management and data flow optimization.
Networking: IP Digital Filtering for fault detection and redundancy switching.
Developed and configured a robust Fault-Tolerant Solution using Kubernetes and Node-Red to ensure high availability and redundancy for industrial automation processes. This system provided seamless failover capabilities and efficient data handling in a mission-critical environment.
Core Contributions
Kubernetes Architecture:
- Designed and implemented a three-node Kubernetes cluster to deliver fault tolerance and scalability.
- Configured services to ensure uninterrupted system operations even during node failures.
Node-Red Redundancy and Control:
- Developed custom Node-Red Flows to manage redundancy between primary and secondary Node-Red instances.
- Implemented IP Digital Filtering to intelligently determine and switch between active and standby instances.
- Created a Node-Red control module to dynamically manage and assign the roles of primary and secondary instances based on system status.
Impact
Delivered a fault-tolerant and highly available system, ensuring seamless operation in critical automation workflows. The intelligent redundancy design minimized downtime and enhanced system reliability, setting a standard for scalable and robust industrial solutions.
Client Information
Client Name: CSE ICON | Pioneer Natural Resources
Location: Dallas, Texas
Year: 2021–2023
Industrial Network Cyber Security Tool (Splunk & Node-Red)
Technological Highlights
SCADA Integration: Ignition SCADA API.
Programming: Node-Red for flow programming and Node.js for custom scripting.
Visualization and Analytics: Splunk Platform for data visualization and analysis.
Networking: APIs for communication with network and radio devices.
Developed and configured a robust Cyber Security Tool to monitor and visualize data from industrial networks, including SCADA applications, network appliances, and radio communications. This tool integrated multiple data sources into a unified platform to enhance security and operational visibility.
Core Contributions
Data Acquisition and Integration:
- Configured APIs to collect data from Ignition SCADA Applications, network appliances, and radio network devices.
- Developed custom API interfaces using Node-Red, ensuring seamless integration with hardware and software from various manufacturers.
Custom Node Development:
- Utilized Node.js to create custom nodes in Node-Red for handling complex data processing and API interactions.
- Ensured efficient and secure data transmission across the industrial network.
Cybersecurity Visualization with Splunk:
- Built a comprehensive Splunk Dashboard to visualize real-time cybersecurity metrics for the entire industrial network.
- Designed dashboards to display key insights such as device health, communication statuses, and potential security threats.
Impact
This project successfully delivered an advanced cybersecurity tool, providing real-time insights into the health and security of industrial networks. The Splunk Dashboard empowered operators to identify and mitigate potential threats proactively, enhancing overall network reliability and security.
Client Information
Client Name: CSE ICON | Pioneer Natural Resources
Location: Dallas, Texas
Year: 2021–2023
Enterprise Cygnet SCADA & IIoT System (Cloud) & West Texas Operations Support
Technological Highlights
SCADA Platform: Cygnet SCADA and Edge Platform.
Cloud Infrastructure: Microsoft Azure.
IIoT Protocols: MQTT/TLS for edge-to-cloud communication.
Visualization Tools: Cygnet Vision, Canvas, DDS, FMS, FS, and PS
Developed and configured an enterprise-level SCADA system for 500 wells using the Cygnet SCADA and Edge Platform. This project included migrating the existing system to a cloud-based infrastructure on Microsoft Azure, creating templates for new facilities, and providing operational support for field personnel across West Texas.
Core Contributions
SCADA System Development and Migration:
- Configured and developed a 500 Well SCADA System using the Cygnet SCADA and Cygnet Edge Platform.
- Migrated the Cygnet SCADA system from an on-premises data center to Microsoft Azure, enabling enhanced scalability and remote accessibility.
Template and Facility Development:
- Designed and implemented new facilities/assets and templates within Cygnet Vision, Canvas, DDS, FMS, FS, and PS, ensuring alignment with active drilling and construction schedules.
- Standardized templates for efficient replication and consistency across new installations.
Field and Operational Support:
- Provided extensive support to Greenfield, Brownfield, and Maintenance Personnel in the Electrical, Automation, Communications, and Artificial Lift disciplines.
- Ensured seamless operations through regular troubleshooting and configuration updates.
IIoT Integration and Proof-of-Concept:
- Developed a Proof-of-Concept (POC) for publishing real-time data from the edge to Microsoft IoT using MQTT/TLS, demonstrating secure and reliable data transmission.
Impact
This project delivered a robust and scalable SCADA system, enhanced by a successful migration to a cloud-based infrastructure. The integration of IIoT technologies and standardized templates improved operational efficiency, while the proof-of-concept demonstrated the feasibility of secure edge-to-cloud data publishing.
Client Information
Client Name: CSE ICON | Noble Energy
Location: Pecos, Texas | Houston Texas
Year: 2019–2021
Cygnet SCADA System Engineering Study
Technological Highlights
SCADA Platform: Cygnet SCADA System.
Analysis Tools: System architecture evaluation methodologies and performance analytics.
Conducted a comprehensive engineering assessment of Summit Midstream’s Cygnet SCADA System Platform Architecture, focusing on Primary/Secondary and Disaster Recovery systems. Delivered actionable insights and cost estimates to improve system reliability and scalability.
Core Contributions
System Architecture Assessment:
- Performed a detailed evaluation of the Primary/Secondary SCADA systems to identify potential vulnerabilities and performance bottlenecks.
- Assessed the Disaster Recovery Enterprise Systems, ensuring compliance with operational and business continuity requirements.
Engineering Study Report:
- Compiled findings into a comprehensive Engineering Study Report, highlighting critical areas for improvement.
- Provided actionable recommendations to optimize system performance, scalability, and disaster recovery capabilities.
Cost Estimation and Planning:
- Delivered a detailed cost estimate for executing the critical upgrades and recommendations identified in the study.
- Facilitated budget planning and prioritization for effective implementation.
Impact
The project provided Summit Midstream with a clear roadmap to enhance the reliability and efficiency of their SCADA platform. The engineering study empowered the client to make informed decisions about system upgrades and disaster recovery enhancements.
Client Information
Client Name: CSE ICON | Summit Midstream
Location: Houston Texas
Year: 2019
McAlester Wonderware SCADA System Engineering Study & Migration
Technological Highlights
SCADA Platform: Wonderware System Platform.
Integration Tools: Bont Software System for seamless architecture migration.
Conducted an in-depth onsite assessment of the Wonderware System Platform architecture for the “STACK” business unit, identifying areas for improvement. Supported the migration to a distributed architecture, enhancing system reliability and performance.
Core Contributions
System Assessment:
- Performed a detailed onsite evaluation of the existing Wonderware System Platform Architecture, identifying inefficiencies and areas requiring upgrades.
- Analyzed system performance and bottlenecks to formulate actionable recommendations.
Migration to Distributed Architecture:
- Supported the migration to a Distributed Architecture for the Wonderware System Platform integrated with the Bont Software System.
- Enhanced system scalability and reliability, ensuring improved performance in handling operational demands.
Improved System Reliability:
- Implemented architectural changes to reduce downtime and ensure consistent data availability across the SCADA network.
Impact
The project delivered a modernized and reliable SCADA system for the “STACK” business unit, significantly improving system performance and operational efficiency. The migration to a distributed architecture enabled the system to handle increased loads with minimal downtime.
Client Information
Client Name: CSE ICON | Markwest | Marathon
Location: McAlester, Oklahoma
Year: 2019
Kingfisher Wonderware SCADA System Engineering Study & Migration
Technological Highlights
SCADA Platform: Wonderware System Platform.
Integration Tools: Bont Software System for distributed system implementation.
Performed an onsite assessment and supported the migration of the Wonderware System Platform Architecture for the “STACK” business unit at Kingfisher, Oklahoma. The project focused on enhancing reliability and system performance through the adoption of a distributed architecture.
Core Contributions
System Assessment:
- Conducted a comprehensive onsite evaluation of the Wonderware System Platform Architecture, identifying inefficiencies and performance gaps.
- Analyzed operational demands and provided actionable insights to optimize system functionality.
Distributed Architecture Migration:
- Assisted in migrating the existing SCADA setup to a Distributed Architecture, integrating it with the Bont Software System.
- Improved system scalability and ensured efficient resource utilization across the architecture.
Reliability and Performance Improvements:
- Implemented upgrades to reduce system downtimes and enhance data consistency and availability.
- Addressed performance bottlenecks, ensuring a robust and resilient SCADA network.
Impact
The project successfully delivered a high-performing, reliable SCADA system tailored to the operational needs of the “STACK” business unit. The migration to a distributed architecture significantly improved system performance and reduced operational risks.
Client Information
Client Name: CSE ICON | Markwest | Marathon
Location: Kingfisher, Oklahoma
Year: 2019
1000 Well Real-Time & Manual SCADA & Production Reporting System
Technological Highlights
SCADA Platform: Ignition SCADA.
Scripting: Python for SCADA automation and VB scripting for data integration.
Database: SQL Server for data storage and warehousing.
Developed and configured a robust SCADA system to monitor and report on 1,000 wells using the Ignition SCADA platform. This project involved creating efficient data processes, integrating third-party systems, and designing custom reporting solutions to support daily and monthly production analysis.
Core Contributions
SCADA System Development:
- Configured a 1,000 Well SCADA System within the Ignition platform, ensuring real-time monitoring and manual override capabilities for enhanced operational control.
- Developed and modified Python scripting to enable template-driven data processes, streamlining the creation of repetitive workflows.
Custom Reporting Solutions:
- Designed and implemented custom daily and monthly reports using Python scripting within Ignition, providing actionable insights into production metrics.
- Ensured reports were dynamic and easily customizable to meet various operational needs.
Third-Party Integration Utilities:
- Developed server-side VB scripts to import data from third-party systems into the Ignition environment, enhancing data completeness and system interoperability.
Database Architecture Enhancements:
- Designed and modified the SQL Server Database Architecture to support efficient data warehousing and system configuration.
- Optimized database performance to handle large volumes of real-time and historical data.
Impact
This project successfully delivered a scalable SCADA solution for DJR Energy, enabling real-time and manual monitoring of 1,000 wells. The integration of third-party systems and the development of custom reporting tools significantly enhanced operational efficiency and decision-making.
Client Information
Client Name: CSE ICON | DJR Energy
Location: Denver, Colorado
Year: 2018
Video Stitching/Object Recognition & Tracking/Machine Learning System Proof of Concept
Technological Highlights
Hardware Platform: NVIDIA Jetson TX2, Pixy Motion Cameras, commercial web cameras.
Programming Languages: Python, C++, Linux Shell Scripting.
Visualization: Ignition SCADA on Linux for data display and machine learning verification.
Developed a proof-of-concept system integrating advanced machine learning, object recognition, and video stitching technologies for a billiards tournament application. This innovative solution utilized NVIDIA Jetson TX2 hardware to enable real-time object tracking and data visualization.
Core Contributions
Firmware and Software Development:
- Designed and implemented object recognition and tracking algorithms for seamless video stitching and machine learning applications.
- Developed custom firmware to optimize system performance on the NVIDIA Jetson TX2 platform.
Hardware Integration:
- Designed hardware solutions integrating Pixy Motion Cameras and commercial off-the-shelf web cameras.
- Provided custom device drivers written in Python and C++ for use within the Linux Ubuntu environment.
Machine Learning Data Application:
- Created a Machine Learning Data Verification Application using Ignition on the Linux platform.
- Enabled real-time visualization of system data and machine learning outputs for enhanced usability and analysis.
Impact
The proof-of-concept successfully demonstrated real-time video stitching, object recognition, and tracking capabilities, positioning i3Design as a leader in innovative applications for sports and entertainment analytics. The project showcased the potential for scalable machine learning solutions in hardware-constrained environments.
Client Information
Client Name: i3Design, LLC
Location: Oklahoma City, Oklahoma
Year: 2018
2014 – 2017 Notable Projects
Fisher ROC 800 IIoT Firmware & Software Proof of Concept
Technological Highlights
Hardware Platform: Fisher ROC 800 Series RTU.
Programming Languages: C, Microsoft C++.NET.
IIoT Protocols: MQTT, TLS.
Cloud Platform: Windows Azure IoT Hub.
Developed a comprehensive proof of concept for the Fisher ROC 800 Series RTU, enabling it to support modern IIoT protocols and secure communication. The project involved firmware updates, protocol development, and integration with Windows Azure IoT Hub to showcase enhanced connectivity and data security.
Core Contributions
Firmware Development:
- Updated the firmware for Fisher ROC 800 Series RTUs to support MQTT, TLS, and Certificate Security on a Linux platform using the C programming environment.
Protocol and Security Integration:
- Developed an MQTT protocol implementation for the Fisher ROC 800 Series RTU using Microsoft C++.NET, ensuring compatibility with modern IoT communication standards.
- Built TLS (Transport Layer Security) features for MQTT communication in Microsoft C++.NET, providing robust encryption and data integrity.
Data Broker Development:
- Designed and implemented a TLS Data Broker to facilitate secure command processing and data exchange between the Fisher ROC 800 RTU and the Windows Azure IoT Hub.
Presentation and Collaboration:
- Presented the proof of concept at the Microsoft Technology Center in Houston, Texas, showcasing the RTU’s enhanced capabilities and integration with cloud IoT services.
Impact
The project demonstrated the viability of modernizing legacy RTUs with IIoT capabilities, enabling Emerson and Microsoft to explore advanced applications for remote monitoring and control. The secure and scalable integration with Azure IoT Hub positioned the Fisher ROC 800 as a future-ready solution for industrial automation.
Client Information
Client Name: Emerson | Microsoft
Location: Houston, Texas
Year: 2017–2018
Acoustic Panel Sheeter Stacker Machine Motion Control & Safety System
Technological Highlights
PLC Platform: Allen Bradley Control Logix L72S.
HMI Platform: Allen Bradley FactoryTalk View SE Station.
Vision System: Cognex Vision Cameras.
Safety Systems: Keyence Area Scanners, Light Curtains.
Motion Control: Allen Bradley Kinetix Servo Drives.
Designed and implemented the Motion Control and Safety System for an acoustic panel sheeter stacker machine, ensuring efficient operation and compliance with safety standards. This project included PLC programming, HMI development, vision system configuration, and comprehensive safety measures for machine guarding.
Core Contributions
Motion Control System Development:
- Programmed and configured the motion control system on the Allen Bradley Control Logix L72S Platform to manage precise operations of the sheeter stacker machine.
- Programmed Allen Bradley Kinetix Servo Drives for both the operator side and drive side, ensuring smooth and synchronized movements.
HMI Development:
- Developed and configured an HMI interface on the Allen Bradley FactoryTalk View SE Station Platform, providing operators with real-time machine monitoring and control capabilities.
Vision System Integration:
- Configured Cognex Vision Cameras for material inspection during pre- and post-operations, enhancing quality control.
Machine Safety Implementation:
- Designed and calculated safety distance requirements for machine guarding using Keyence Area Scanners and Light Curtains, ensuring operator safety.
- Integrated safety systems with the motion control logic for seamless operation without compromising safety protocols.
Documentation and Support:
- Developed detailed project documentation, including:
- Machine Control Narrative
- Cause & Effect Matrix
- I/O List
- Safe Guard Drawings
- Instrumentation/Electrical Drawings
- Provided onsite testing, troubleshooting, and commissioning support to ensure smooth project execution.
Impact
The project successfully delivered a high-performing and safe sheeter stacker machine. The integration of motion control, vision systems, and advanced safety measures improved production efficiency, ensured compliance with safety regulations, and minimized operational risks.
Client Information
Client Name: Doerfer | Wright Industries
Location: Nashville, Tennessee
Year: 2017
Commercial Saltwater Disposal Tank Level Instrumentation & Control System Upgrade
Technological Highlights
Instrumentation: Endress Hauser (4-20 mA HART).
Control Systems: Allen Bradley Compact Logix L33ER.
HMI Platforms: FactoryTalk View ME, Iconics Genesis 64.
Communication Protocols: Modbus RTU.
Engineered and upgraded the Saltwater Disposal Tank Level Instrumentation and Control System to enhance measurement accuracy and process reliability. This project included designing instrumentation, upgrading PLC and HMI systems, and providing on-site commissioning support.
Core Contributions
Instrumentation and Electrical Design:
- Designed tank level instrumentation to measure water and oil levels using Endress Hauser (4-20 mA HART) and integrated with the Tank Logix (Modbus RTU) Platform.
- Provided instrument and electrical design for new additions to saltwater tanks, ensuring seamless communication and integration.
PLC Programming and Configuration:
- Updated and streamlined PLC logic on the Allen Bradley Compact Logix L33ER Platform to support new instrumentation and enhance system reliability.
HMI Programming and Configuration:
- Developed and updated HMI screens for the Commercial Saltwater Disposal Process Control System using:
- Allen Bradley FactoryTalk View ME for control room and lane-specific HMIs (Lane 1–5).
- Iconics Genesis 64 Platform for improved visualization and communication with new instrumentation.
Documentation and Reporting:
- Created comprehensive project documentation, including:
- I/O List
- Modbus Datasheet
- Instrumentation/Electrical Drawings
Onsite Support and Commissioning:
- Provided hands-on startup and commissioning support to ensure the smooth operation of upgraded systems.
Impact
This project delivered a modernized control system for saltwater disposal tanks, improving measurement accuracy, system reliability, and operator efficiency. The upgraded instrumentation and streamlined PLC logic significantly reduced operational downtime and enhanced overall system performance.
Client Information
Client Name: Disposal Solutions
Location: Okemah, Oklahoma
Year: 2017
Buffalo Wallow Compressor Station PLC5 to Compact Logix Upgrade
Technological Highlights
Control Platforms: Allen Bradley Compact Logix L33ER, FactoryTalk View ME, Inductive Automation Ignition.
Documentation Tools: Comprehensive process and control system documentation for operational efficiency.
Led the migration of the Buffalo Wallow Compressor Station control systems from an Allen Bradley PLC5 to a modern Compact Logix L33ER Platform. This project included comprehensive design, programming, and HMI integration, ensuring enhanced system reliability and performance.
Core Contributions
Control System Migration:
Designed and implemented the migration of control systems for Units 6001 and 6002 from Allen Bradley PLC5 to the Compact Logix L33ER Platform, ensuring smooth transition and minimal disruption.
Instrumentation and Electrical Design:
Developed instrument and electrical designs for new additions to Units 6001 and 6002, integrating seamlessly with the upgraded system.
Process Control Development:
Authored the Process Control Narrative and Cause & Effect Matrix for Units 6001 and 6002, detailing operational logic and system behavior. Created a comprehensive Tag Database to support streamlined data processing and control.
PLC and HMI Programming:
Programmed and configured PLC systems for Units 6001 and 6002 using the Allen Bradley Compact Logix L33ER Platform. Developed and configured HMI interfaces for process control systems on:
- FactoryTalk View ME Platform for local operation and monitoring.
- Inductive Automation Ignition Platform for remote access and advanced visualization.
Onsite Support and Documentation:
Provided on-site startup and commissioning support to ensure a successful system transition. Delivered detailed project documentation, including:
- Control Narrative
- Cause & Effect Matrix
- I/O List
- Instrumentation/Electrical Drawings
- Maintenance & Operation Manual
Impact
The project successfully modernized the Buffalo Wallow Compressor Station control systems, significantly improving reliability, scalability, and operational visibility. The migration to the Compact Logix platform reduced system downtime and provided enhanced monitoring capabilities through integrated HMI solutions.
Client Information
Client Name: ONEOK
Location: Briscoe, Texas
Year: 2016–2017
Milton | Saddle Horn Crude Oil Terminals Process Control Systems – Phase 3
Technological Highlights
Control Platforms: Allen Bradley Control Logix L72.
HMI Platforms: Allen Bradley FactoryTalk View ME, Wonderware System Platform (Archestra).
Documentation Tools: Comprehensive technical documentation for operational clarity.
Developed and upgraded the Process Control Systems for the Milton and Saddle Horn Crude Oil Terminals to enable seamless data exchange and control integration. This project focused on updating PLC programming, HMI configurations, and process documentation to support enhanced operational performance.
Core Contributions
Process Control Narrative Development:
Created and updated the Process Control Narrative to define operational workflows and ensure accurate data exchange between the Milton and Saddle Horn Crude Oil Terminals.
Cause & Effect Matrix Development:
Developed a comprehensive Cause & Effect Matrix for both terminals, outlining system responses to specific events for improved safety and reliability.
PLC Programming and Configuration:
Updated the PLC programming for:
- Milton Crude Oil Terminal using the Allen Bradley Control Logix L72 Platform, enabling connection to the Saddle Horn Terminal.
- Saddle Horn Crude Oil Terminal using the same platform, ensuring compatibility and consistent control logic.
HMI Programming and Configuration:
- Updated the Milton Crude Oil Terminal’s HMI on:
- Allen Bradley FactoryTalk View ME Platform for local operations.
- Wonderware System Platform (Archestra) for advanced monitoring and control.
- Configured the Saddle Horn Crude Oil Terminal’s HMI on the Allen Bradley FactoryTalk View ME Platform, maintaining a uniform interface across facilities.
Onsite and Remote Support:
Provided startup and commissioning support, both onsite and remotely, to ensure successful deployment and operation of the integrated systems.
Comprehensive Documentation Development:
Produced detailed project documentation, including:
- Control Narrative
- Cause & Effect Matrix
- I/O List
- Tag Database
- Technical Notes/Whitepapers
- Maintenance & Operation Manual
Impact
This project successfully delivered a fully integrated and updated process control system for the Milton and Saddle Horn Crude Oil Terminals. The enhancements improved operational coordination, system reliability, and safety measures, ensuring seamless control and data exchange between the facilities.
Client Information
Client Name: Saddle Butte Pipeline
Location: LaSalle, Colorado
Year: 2016
Milton Crude Oil Terminal Process Control System – Phase 1 & 2
Technological Highlights
Control Platforms: Allen Bradley Control Logix L72.
HMI Platforms: Allen Bradley FactoryTalk View ME, Wonderware System Platform (Archestra).
Communication Tools: Red Lion Data Station Plus for data exchange.
Documentation Tools: Comprehensive technical documentation to support operations.
Designed and implemented the Process Control System for the Milton Crude Oil Terminal across two phases, focusing on PLC programming, HMI configuration, and seamless data communication. This project also included comprehensive documentation and commissioning support to ensure reliable and efficient operations.
Core Contributions
Process Control Narrative Development:
Developed a detailed Process Control Narrative outlining the operational workflows and logic for the Milton Crude Oil Terminal.
Cause & Effect Matrix Development:
Created a Cause & Effect Matrix to define the system’s automated responses to specific operational conditions, ensuring safety and consistency.
PLC Programming and Configuration:
Configured the Allen Bradley Control Logix L72 Platform for the terminal’s process control system, delivering robust and scalable automation solutions.
Data Gateway Integration:
Programmed and configured the Red Lion Data Station Plus Platform to enable data communication between the Milton Crude Oil Terminal and the White Cliffs LaSalle Terminal Process Control System, ensuring seamless data exchange.
HMI Programming and Configuration:
Configured HMI systems for the terminal’s process control on:
- Allen Bradley FactoryTalk View ME Platform for local operations.
- Wonderware System Platform (Archestra) for advanced visualization and control.
Onsite Startup and Commissioning Support:
Provided hands-on support during startup and commissioning to ensure system readiness and address any operational challenges.
Comprehensive Documentation Development:
Developed project documentation to support future operations and maintenance, including:
- Control Narrative
- Cause & Effect Matrix
- I/O List
- Tag Database
- Technical Notes/Whitepapers
- Maintenance & Operation Manual
Impact
This project established a fully functional and reliable process control system for the Milton Crude Oil Terminal. The integrated data gateway and advanced HMI configurations enhanced operational efficiency and facilitated seamless communication with the White Cliffs LaSalle Terminal.
Client Information
Client Name: Saddle Butte Pipeline
Location: LaSalle, Colorado
Year: 2015–2016
Gas to Liquid Chemical Reactor & Process Design/Virtual Prototype
Technological Highlights
Design Tools: SolidWorks Premium, SolidWorks Flow Simulation.
Materials: Phenolic, platinum, Pyrex.
Electrical Modeling: Etap for high-voltage system validation.
Analysis Tools: Advanced simulation for structural, thermal, and fatigue assessments.
Designed and developed a Gas to Liquid (GTL) Chemical Reactor, integrating high-voltage systems and advanced material engineering. This project included process simulation, structural analysis, and the creation of a virtual prototype to validate operational performance.
Core Contributions
High-Voltage System Design:
Designed a 15 kV high-voltage system to generate an electromagnetic field within the chemical reactor. The voltage was applied across a platinum plate, facilitating the required reactions within the reactor.
Chemical Reactor Engineering:
Developed the reactor design using phenolic and platinum materials with Pyrex tubes, ensuring compatibility with high-voltage operations and chemical stability. This included detailed engineering of:
- Gas Flow
- Fluid Flow
- Pressure Management
- Structural Integrity
- Thermal Regulation
- Mechanical Components
Process Loop Simulation and Modeling:
Utilized SolidWorks Premium and SolidWorks Flow Simulation to simulate and analyze:
- Gas and fluid flow dynamics.
- Pressure variations and thermal impacts.
- Structural integrity under operational stresses.
- Fatigue resistance to ensure long-term durability.
Documentation and Prototyping:
Produced comprehensive project documentation to support design validation and implementation, including:
- Chemical Reactor Design Drawings
- Assembly Drawings
- SolidWorks Models
- Etap Electrical Models
- Test Reports
Impact
The project delivered a virtual prototype of a Gas to Liquid Chemical Reactor, showcasing a robust design and reliable operational characteristics. The comprehensive engineering and process modeling set the foundation for future development and commercialization of GTL technology.
Client Information
Client Name: Turbine Truck Engines | Novo Integrated Sciences
Location: Daytona Beach, Florida / Bellevue, Washington
Year: 2015
2800 Well North Burbank Field SCADA System Wonderware to iFIX Migration
Technological Highlights
SCADA Platform: GE Proficy iFIX.
RTU Platform: Control Micro Systems SCADA pack.
PLC Platform: Allen Bradley Micro Logix, Compact Logix.
Documentation Tools: Comprehensive technical documents for operational support.
Successfully migrated the North Burbank Field SCADA System for 2800 wells from Wonderware to the GE Proficy iFIX Platform, enhancing supervisory control and monitoring capabilities. This project included engineering design, RTU programming, and system commissioning to improve operational efficiency across producing and injection wells.
Core Contributions
SCADA/HMI Programming and Configuration:
Configured the GE Proficy iFIX Platform for the integration and monitoring of 2800 wells, ensuring real-time control and data visualization for producing and injection operations.
Engineering Design of RTU Control Panels:
Designed reliable and scalable Well RTU Control Panels, meeting operational and environmental requirements for the North Burbank Field.
RTU Programming and Configuration:
Developed and configured a standard application on the Control Micro Systems SCADA pack platform for 1450 wells, streamlining system consistency and functionality.
PLC Programming for Gas Measurement:
Updated and optimized PLC programming for gas measurement systems, leveraging:
- Allen Bradley Micro Logix for smaller installations.
- Allen Bradley Compact Logix for wells requiring advanced processing capabilities.
Onsite Startup and Commissioning:
Provided hands-on startup and commissioning support to ensure the successful deployment of the upgraded SCADA system, addressing field-specific challenges.
Comprehensive Documentation Development:
Delivered detailed documentation to support long-term system operation and maintenance, including:
- Control Narrative
- Cause & Effect Matrix
- I/O List
- Instrumentation/Electrical Drawings (I/E Drawings)
- Maintenance & Operation Manual
Impact
The project modernized the SCADA system for 2800 wells, improving operational monitoring, control, and reliability. The migration to the GE Proficy iFIX Platform provided Chaparral Energy with a scalable and efficient system to meet their production and injection monitoring needs.
Client Information
Client Name: Chaparral Energy
Location: Shidler, Oklahoma
Year: 2014
30,000 Horsepower Electric Frac Spread PM Motor & VFD Re-Design
Technological Highlights
Hardware: 600 VAC Permanent Magnetic Motors, Comprehensive Power VFDs.
Software: Linux, C++ for firmware development.
Engineering Tools: Power system analysis and advanced design techniques.
Led the engineering re-design of 600 VAC Permanent Magnetic Motors and Variable Frequency Drives (VFDs) for a 30,000 Horsepower Electric Frac Spread, focusing on improving efficiency and performance. The project included motor design, firmware reconfiguration, and power system analysis.
Core Contributions
Permanent Magnetic Motor Re-Design:
Engineered a re-design of 600 VAC Permanent Magnetic Motors, ensuring optimal performance and reliability for high demand frac spread operations.
Onsite Motor Design and Leadership:
Provided expert motor design and technical leadership at Comprehensive Power in Boston, MA, collaborating closely with the client’s engineering team.
Firmware Re-Design for Variable Frequency Drives:
Developed and implemented a Linux-based firmware re-design for Comprehensive Power’s Variable Frequency Drives (VFDs), resulting in significant efficiency improvements for the Permanent Magnetic Motors.
Power System Analysis:
Conducted a detailed power system analysis of Comprehensive Power’s Motor Test Systems to identify performance enhancements and optimize operational output.
Documentation and Reporting:
Delivered thorough project documentation to support ongoing operation and future development, including:
- Motor Design Drawings
- Engineering Reports
- System Architecture Diagrams
Impact
The project successfully improved the performance and efficiency of the 30,000 Horsepower Electric Frac Spread, ensuring robust and reliable operations for Beusa Energy. The re-design of motors and VFD firmware provided a scalable solution for high-demand industrial applications.
Client Information
Client Name: Beusa Energy | Evolution Well Services
Location: Houston, Texas
Year: 2014
Gas to Liquid Chemical Reactor & Process Design/Virtual Prototype
Technological Highlights
Design Tools: SolidWorks Premium, SolidWorks Flow Simulation.
Materials: Phenolic, platinum, Pyrex.
Electrical Modeling: Etap for high-voltage system validation.
Analysis Tools: Advanced simulation for structural, thermal, and fatigue assessments.
Designed and developed a Gas to Liquid (GTL) Chemical Reactor, integrating high-voltage systems and advanced material engineering. This project included process simulation, structural analysis, and the creation of a virtual prototype to validate operational performance.
Core Contributions
High-Voltage System Design:
Designed a 15 kV high-voltage system to generate an electromagnetic field within the chemical reactor. The voltage was applied across a platinum plate, facilitating the required reactions within the reactor.
Chemical Reactor Engineering:
Developed the reactor design using phenolic and platinum materials with Pyrex tubes, ensuring compatibility with high-voltage operations and chemical stability. This included detailed engineering of:
- Gas Flow
- Fluid Flow
- Pressure Management
- Structural Integrity
- Thermal Regulation
- Mechanical Components
Process Loop Simulation and Modeling:
Utilized SolidWorks Premium and SolidWorks Flow Simulation to simulate and analyze:
- Gas and fluid flow dynamics.
- Pressure variations and thermal impacts.
- Structural integrity under operational stresses.
- Fatigue resistance to ensure long-term durability.
Documentation and Prototyping:
Produced comprehensive project documentation to support design validation and implementation, including:
- Chemical Reactor Design Drawings
- Assembly Drawings
- SolidWorks Models
- Etap Electrical Models
- Test Reports
Impact
The project delivered a virtual prototype of a Gas to Liquid Chemical Reactor, showcasing a robust design and reliable operational characteristics. The comprehensive engineering and process modeling set the foundation for future development and commercialization of GTL technology.
Client Information
Client Name: Turbine Truck Engines | Novo Integrated Sciences
Location: Daytona Beach, Florida / Bellevue, Washington
Year: 2015
2800 Well North Burbank Field SCADA System Wonderware to iFIX Migration
Technological Highlights
SCADA Platform: GE Proficy iFIX.
RTU Platform: Control Micro Systems SCADA pack.
PLC Platform: Allen Bradley Micro Logix, Compact Logix.
Documentation Tools: Comprehensive technical documents for operational support.
Successfully migrated the North Burbank Field SCADA System for 2800 wells from Wonderware to the GE Proficy iFIX Platform, enhancing supervisory control and monitoring capabilities. This project included engineering design, RTU programming, and system commissioning to improve operational efficiency across producing and injection wells.
Core Contributions
SCADA/HMI Programming and Configuration:
Configured the GE Proficy iFIX Platform for the integration and monitoring of 2800 wells, ensuring real-time control and data visualization for producing and injection operations.
Engineering Design of RTU Control Panels:
Designed reliable and scalable Well RTU Control Panels, meeting operational and environmental requirements for the North Burbank Field.
RTU Programming and Configuration:
Developed and configured a standard application on the Control Micro Systems SCADA pack platform for 1450 wells, streamlining system consistency and functionality.
PLC Programming for Gas Measurement:
Updated and optimized PLC programming for gas measurement systems, leveraging:
- Allen Bradley Micro Logix for smaller installations.
- Allen Bradley Compact Logix for wells requiring advanced processing capabilities.
Onsite Startup and Commissioning:
Provided hands-on startup and commissioning support to ensure the successful deployment of the upgraded SCADA system, addressing field-specific challenges.
Comprehensive Documentation Development:
Delivered detailed documentation to support long-term system operation and maintenance, including:
- Control Narrative
- Cause & Effect Matrix
- I/O List
- Instrumentation/Electrical Drawings (I/E Drawings)
- Maintenance & Operation Manual
Impact
The project modernized the SCADA system for 2800 wells, improving operational monitoring, control, and reliability. The migration to the GE Proficy iFIX Platform provided Chaparral Energy with a scalable and efficient system to meet their production and injection monitoring needs.
Client Information
Client Name: Chaparral Energy
Location: Shidler, Oklahoma
Year: 2014
30,000 Horsepower Electric Frac Spread PM Motor & VFD Re-Design
Technological Highlights
Hardware: 600 VAC Permanent Magnetic Motors, Comprehensive Power VFDs.
Software: Linux, C++ for firmware development.
Engineering Tools: Power system analysis and advanced design techniques.
Led the engineering re-design of 600 VAC Permanent Magnetic Motors and Variable Frequency Drives (VFDs) for a 30,000 Horsepower Electric Frac Spread, focusing on improving efficiency and performance. The project included motor design, firmware reconfiguration, and power system analysis.
Core Contributions
Permanent Magnetic Motor Re-Design:
Engineered a re-design of 600 VAC Permanent Magnetic Motors, ensuring optimal performance and reliability for high demand frac spread operations.
Onsite Motor Design and Leadership:
Provided expert motor design and technical leadership at Comprehensive Power in Boston, MA, collaborating closely with the client’s engineering team.
Firmware Re-Design for Variable Frequency Drives:
Developed and implemented a Linux-based firmware re-design for Comprehensive Power’s Variable Frequency Drives (VFDs), resulting in significant efficiency improvements for the Permanent Magnetic Motors.
Power System Analysis:
Conducted a detailed power system analysis of Comprehensive Power’s Motor Test Systems to identify performance enhancements and optimize operational output.
Documentation and Reporting:
Delivered thorough project documentation to support ongoing operation and future development, including:
- Motor Design Drawings
- Engineering Reports
- System Architecture Diagrams
Impact
The project successfully improved the performance and efficiency of the 30,000 Horsepower Electric Frac Spread, ensuring robust and reliable operations for Beusa Energy. The re-design of motors and VFD firmware provided a scalable solution for high-demand industrial applications.
Client Information
Client Name: Beusa Energy | Evolution Well Services
Location: Houston, Texas
Year: 2014
75 MMSCFD North Burbank CO2 Gas Recycle Plant Safety Control System
Technological Highlights
Control Platform: Allen Bradley Control Logix L61.
HMI Platform: Allen Bradley FactoryTalk View ME.
Electrical Components: Cooper 15KV Reclosers, GE Multilin Soft Starters.
Network Infrastructure: Industrial Managed Network.
Engineered and implemented the Safety Control System for the 75 MMSCFD North Burbank CO2 Gas Recycle Plant. This project involved PLC programming, HMI development, and the integration of safety-critical components, ensuring compliance with industrial safety standards and robust plant operation.
Core Contributions
PLC Programming and Configuration:
Developed and configured the Allen Bradley Control Logix L61 Platform to manage the safety systems of the CO2 Gas Recycle and Processing Plant. This ensured reliable and efficient control of safety-critical operations.
HMI Programming and Configuration:
Designed and implemented HMI systems on the Allen Bradley FactoryTalk View ME Platform to provide operators with real-time monitoring and control of safety functions.
Intelligent Electrical Reclosers:
Configured Cooper 15KV Reclosers for utility incoming power management, enabling enhanced fault isolation and power reliability.
GE Multilin Soft Starter Configuration:
Set up and optimized GE Multilin Soft Starters to ensure smooth startup and operation of critical electrical components.
Industrial Managed Network Design:
Designed and implemented a robust managed network to support all buildings and associated devices within the plant, ensuring secure and reliable communication.
Onsite Startup and Commissioning Support:
Provided hands-on support during startup and commissioning to ensure all systems were operational and met project requirements.
Comprehensive Documentation Development:
Produced detailed documentation to support plant safety and maintenance, including:
- Control Narrative
- Cause & Effect Matrix
- I/O List
- Maintenance & Operation Manual
Impact
The project delivered a robust and reliable Safety Control System for the North Burbank CO2 Gas Recycle Plant, ensuring compliance with safety standards and improving operational efficiency. The integrated solution provided Chaparral Energy with enhanced control and monitoring capabilities for critical safety functions.
Client Information
Client Name: Chaparral Energy
Location: Shidler, Oklahoma
Year: 2013–2014
75 MMSCFD North Burbank CO2 Gas Recycle Plant Process Control System
Technological Highlights
Control Platforms: Allen Bradley Control Logix L61, Compact Logix L33.
HMI Platforms: Allen Bradley FactoryTalk View ME.
Electrical Components: GE Multilin Soft Starters, Cutler Hammer VFDs.
Network Infrastructure: Industrial Managed Network.
Instrumentation: Pressure, temperature, and flow transmitters.
Engineered and deployed a comprehensive Process Control System for the 75 MMSCFD North Burbank CO2 Gas Recycle Plant. This project included PLC programming, HMI development, compressor control, and network infrastructure to enhance plant efficiency and ensure robust operational capabilities.
Core Contributions
Process Control System Programming:
Configured the Allen Bradley Control Logix L61 Platform for the CO2 Gas Recycle and Processing Plant, enabling precise control and monitoring of the recycling process.
Dehydration System Integration:
Developed the PLC programming for the Dehydration System on the Allen Bradley Compact Logix L33 Platform and configured the HMI on the Allen Bradley FactoryTalk View ME Platform, ensuring seamless integration with plant operations.
Compressor Control:
- Programmed and configured PLC systems for 16 electric compressors using the Allen Bradley Control Logix L61 Platform.
- Designed HMI interfaces for the compressors on the FactoryTalk View ME Platform, providing intuitive control and real-time feedback.
Electrical Component Configuration:
- Set up GE Multilin Soft Starters for safe and efficient electrical component startup.
- Configured Cutler Hammer Motor Control Center VFDs and other motor starters to optimize power usage and performance.
Network Design and Implementation:
Designed and implemented a secure and reliable Industrial Managed Network, supporting seamless communication across all plant buildings and devices.
Instrumentation Calibration and Tuning:
Performed onsite calibration and tuning of critical instrumentation, including pressure, temperature, and flow transmitters, to ensure optimal process accuracy.
Onsite Startup and Commissioning:
Provided hands-on startup and commissioning support to guarantee smooth integration and operation of all systems.
Comprehensive Documentation Development:
Delivered thorough documentation to support plant operations, including:
- Control Narrative
- Cause & Effect Matrix
- I/O List
- Maintenance & Operation Manual
Impact
This project equipped Chaparral Energy with a highly reliable and efficient Process Control System for the CO2 Gas Recycle Plant. The integration of advanced controls, electrical systems, and network infrastructure improved plant operations and ensured compliance with industry standards.
Client Information
Client Name: Chaparral Energy
Location: Shidler, Oklahoma
Year: 2013–2014
Internet-Based Enterprise Artificial Lift Well Monitoring System
Technological Highlights
Development Platforms: Microsoft C#.NET, C++.NET, WPF.
Hardware Design: Altium for DataBridge RTU/Gateway.
Protocols Supported: Modbus, TCP/IP, Ethernet/IP, MQTT.
Visualization Tools: VistaControl for HMI and data management.
Designed and implemented an Internet-Based Enterprise Well Monitoring System for artificial lift wells, leveraging Microsoft.NET technologies. This solution included custom hardware and firmware design, SCADA server development, and visualization applications to enhance data management, alarm handling, and operational monitoring.
Core Contributions
System Architecture and Engineering Design:
Developed the system architecture for a custom Microsoft.NET-based well monitoring system, providing a robust framework for reliable data acquisition and processing.
Hardware and Firmware Design:
- Designed the DataBridge RTU/Gateway using Altium for hardware design.
- Developed firmware in C#.NET and C++.NET to support communication with existing automation protocols, including:
- Modbus
- TCP/IP
- Ethernet/IP
- MQTT
- Implemented a Store and Forward methodology to prevent data loss during communication with the CoreControl SCADA Server.
Wireless Communication Specifications:
Specified appropriate wireless communication radio routing to optimize data transfer and minimize latency.
SCADA Server Development:
- Programmed and deployed the CoreControl SCADA Server using Microsoft C#.NET and WPF, enabling:
- Historical data storage.
- Alarm data handling.
- Real-time process data visualization.
- Developed an Alarm Notification and Callout System for enhanced alert management.
Visualization Application Development:
- Created the VistaControl Visualization Application using Microsoft C#.NET, providing capabilities for:
- Creating custom HMI screens.
- Managing well tags, alarm definitions, and active alarms.
- Logging historical data.
- Configuring devices, generating reports, and monitoring wells.
Installation and Deployment Support:
Offered hands-on installation and deployment assistance to ensure seamless integration of the system into the operational environment.
Comprehensive Documentation:
Delivered project documentation to support long-term operation and maintenance, including a Maintenance & Operation Manual.
Impact
The project provided Occidental Petroleum with a scalable, internet-based monitoring system, improving data reliability, alarm management, and operational oversight. The custom solution enabled better decision-making through real-time data visualization and robust SCADA server capabilities.
Client Information
Client Name: Occidental Petroleum
Location: Muscat, Oman
Year: 2013–2014
2012 – 2013 Notable Projects
30,000 Horsepower Electric Frac Spread Process Control System
Technological Highlights
Hardware Platform: National Instruments Compact RIO.
Software Platform: National Instruments LabVIEW, LabVIEW Real-Time, LabVIEW FPGA.
Control Systems: Custom applications tailored to high horsepower frac spread requirements.
Core Contributions
Engineering Design:
Developed a comprehensive Process Control System architecture tailored for high demand frac spread operations, ensuring seamless integration and operational reliability.
PAC Programming and Configuration:
Programmed and configured the National Instruments Compact RIO Platform to manage and control frac spread operations, leveraging its robust processing and modular I/O capabilities.
HMI/Application Programming:
Developed HMI and control applications on the National Instruments LabVIEW Platform, utilizing:
- LabVIEW Real-Time for precise, time-sensitive operations.
- LabVIEW FPGA for high-performance control and monitoring capabilities from the local data van.
Documentation Development:
Delivered detailed project documentation to ensure long-term operability and maintainability, including:
- Maintenance & Operation Manual
Impact
This project delivered a reliable, high-performance Process Control System for Beusa Energy and Evolution Well Services. The integrated system provided precise control and monitoring capabilities, significantly enhancing operational efficiency and reliability for the 30,000 Horsepower Electric Frac Spread.
Client Information
Client Name: Beusa Energy | Evolution Well Services
Location: Houston, Texas
Year: 2013–2014
ESP Automated Cable Test System
Technological Highlights
HMI Platform: National Instruments LabVIEW.
Control Platform: National Instruments Compact RIO.
High-Voltage Components: 0–40 kV Digital Power Supply, Fiber-Optic Isolation Modules, High-Voltage Switching Relays.
Compliance Standards: IEEE 1017.
Control Panel Certification: UL 508A.
Designed and implemented a sophisticated ESP Automated Cable Test System to perform high voltage testing and qualification of electrical submersible pump (ESP) cables. The system integrated advanced hardware, custom control panel design, and compliance with industry standards to ensure precision and safety.
Core Contributions
HMI Programming and Configuration:
Developed and configured the HMI Control Room Interface using the National Instruments LabVIEW Platform, providing intuitive control and monitoring of test operations.
Control and Data Acquisition Programming:
Programmed the National Instruments Compact RIO Platform for high voltage testing and data acquisition, enabling real-time monitoring and control during qualification processes.
UL 508A Control Panel Design and Fabrication:
- Designed a UL 508A-certified Control Panel specifically for the cable test system, ensuring compliance with safety and operational standards.
- Fabricated and certified the control panel to meet stringent industrial requirements.
High-Voltage Digital Power Supply Design:
- Engineered a 0–40 kV Digital Power Supply for precise voltage control and leakage current monitoring, enhancing test reliability.
- Designed a Fiber-Optic Isolation Module to enable secure communication with the high-voltage power supply via USB and Serial interfaces.
High-Voltage Switching and Discharge Design:
- Designed a High-Voltage Switching Relay Section for managing cable lead switching, grounding, and high-voltage discharge through 10MΩ resistance, ensuring operational safety.
Testing Standards Compliance:
Developed the system to align with IEEE 1017 Standard for electrical testing and qualification processes.
Onsite Startup and Commissioning Support:
Provided comprehensive onsite support to ensure successful system deployment and functionality.
Impact
This project delivered a robust and precise ESP Automated Cable Test System for GE Oil & Gas, ensuring reliable high voltage testing and qualification processes. The system’s design enhanced operational efficiency while maintaining industry-standard safety and compliance.
Client Information
Client Name: GE Oil & Gas
Location: Oklahoma City, Oklahoma
Year: 2013
10,000 Well Production SCADA System
Technological Highlights
HMI Platform: Cygnet SCADA System.
Development Environment: Microsoft.NET (C#).
Dashboards: Custom-built financial and production forecasting tools.
Assisted in design and implementation of a scalable SCADA System for 10,000 wells and associated facilities across multiple shale formations, including Barnett, Fayetteville, Haynesville, and Marcellus. This project focused on developing a template-driven HMI and executive dashboards to enable efficient data visualization and production forecasting.
Core Contributions
Template-Driven HMI Design:
Engineered a Cygnet Human Machine Interface (HMI) framework, utilizing a template-driven approach to manage and monitor 10,000 wells and associated assets efficiently. This design ensured consistency and scalability across multiple sites.
Dashboards for Executive Management:
Developed dashboards in the Microsoft.NET (C#) environment to transform production data from Cygnet into actionable financial information. These dashboards provided real-time insights and improved decision-making for production forecasting.
Shale Formation Coverage:
Integrated data from wells and facilities spanning the Barnett, Fayetteville, Haynesville, and Marcellus shale formations, offering a unified view of operations.
Engineering and Design Support:
Provided end-to-end engineering and design support, ensuring the SCADA system met operational requirements and streamlined management across large-scale operations.
Impact
This project delivered a robust and scalable SCADA System for Chesapeake Energy, enabling effective monitoring and management of 10,000 wells across diverse shale formations. The integration of executive dashboards allowed real-time production forecasting, driving operational efficiency and strategic decision-making.
Client Information
Client Name: Chesapeake Energy
Location: Oklahoma City, Oklahoma
Year: 2012–2013