Smarter Oilfield Operations: DSI and Rockwell Automation Drive Major Energy Savings with Regenerative Technology
In oil and gas, every minute of downtime costs money, and every watt of wasted energy adds up fast. Across the industry, producers are looking for ways to utilize smarter oilfield operations for oil and gas production systems, lower operating costs, and meet ambitious sustainability goals.
At Design Solutions & Integration (DSI), that challenge is more than a project; it’s a mission. Through a long-standing partnership with Rockwell Automation, DSI recently helped a major global energy company achieve significant energy savings through an oil and gas production modernization initiative using regenerative drive technology.
Leading that effort was Casey Johnston, President of DSI, who brings decades of experience in industrial automation and control systems. “Our goal,” says Johnston, “is to help customers modernize smarter and to take advantage of proven technology that pays for itself in efficiency, safety, and long-term reliability.”
This project saved energy and showed what can happen when deep technical experience, trusted partnerships, and field-proven execution come together to modernize critical operations.
From Challenge to Opportunity: Smarter Oilfield Operations
For many producers, modernization can feel like a daunting step. Equipment is aging, costs are rising, and sustainability targets are tightening.
In this project, the customer faced exactly that situation. An extensive network of well-pad operations powered by older drive systems that consumed large amounts of energy and required constant maintenance.
For an example of smarter oilfield operations, check out this case study:
Collaborating with Rockwell Automation, DSI designed an energy-efficient solution using PowerFlex® 755TR regenerative drives. These advanced VFDs recover and repurpose energy that would otherwise be wasted as heat, improving performance, and sustainability.
The results speak for themselves. With only 12% of the rollout complete, the customer is already seeing major improvements in energy efficiency and expects to achieve more than $3 million per month in savings once the system is fully implemented (Source: Rockwell Automation, 2024).
“The numbers are impressive,” Johnston notes, “but what really matters is the stability and predictability it brings to daily operations. That’s what our customers value most.”
The Power of Partnership: DSI and Rockwell Automation
Behind this success is a partnership built on trust, technical expertise, and a shared vision for smarter oilfield operations.
DSI has been a Rockwell Automation PartnerNetwork™ system integrator for years, serving energy and industrial clients across North America. That relationship gives DSI’s engineering and field teams access to cutting-edge technology, training, and collaboration tools while allowing them to integrate Rockwell’s solutions seamlessly into real-world operations.
“Partnership is more than a logo on a slide deck,” Johnston explains. “It means working side-by-side to make sure the technology performs exactly how the customer needs it to. Rockwell gives us that support, and our team brings the on-site experience to make it real.”
From automation design and drive configuration to commissioning and long-term support, DSI’s vertically integrated structure allows every project to move faster and deliver consistent results.
This combination of global innovation and local execution has become DSI’s hallmark, helping producers take the leap from legacy systems to modern, efficient operations with confidence.
Regenerative Drive Technology: How It Works
At the heart of this oil and gas production modernization is regenerative drive technology, a system that captures the energy normally lost during braking or deceleration and channels it back into the power system.
In oilfield applications, where pumps, compressors, and lift systems run continuously, the energy potential is massive. Instead of dissipating that excess power as heat, regenerative drives send it back to the grid or to other active loads, cutting waste and reducing the need for additional cooling infrastructure.
For the customer, that translates into measurable results:
- Lower power consumption and demand charges
- Reduced heat output and maintenance costs
- Extended equipment life
- Smaller carbon footprint
Johnston puts it simply: “Regenerative drive systems help our customers do more with what they already have. It’s modernization with purpose.”
Building Smarter, Safer, and More Sustainable Operations
DSI’s work doesn’t stop with technology. Every oil and gas production modernization project begins with a focus on safety, quality, and real-world performance.
As an employee-owned company, DSI takes pride in the accountability and craftsmanship of its teams. Each project, whether automation, fabrication, or field service, is backed by experts who understand how small design decisions can impact production uptime, maintenance, and safety in demanding oilfield environments.
That same approach shaped this project. From initial assessment and design through installation and verification, DSI coordinated tightly with the customer and Rockwell’s engineering team to ensure compliance, safety certifications, and seamless system performance.
“Our people know what it takes to get these systems right,” says Johnston. “That means not just meeting technical specs, but making sure operators in the field can trust the equipment every single day.”
This project also reflects the expertise and dedication of the DSI team behind the scenes. Chris Caley led the technical effort, while doing the heavy lifting on the operations and electrical side to ensure the system performed reliably in the field. Dave Thompson and Brian Evans designed the packaged product that brought the entire solution together, by combining technical precision with practical, field-ready design. Their combined contributions were essential in turning concept into execution, and in delivering results that exceed expectations.
Why Smarter Oilfield Operations Matter Now
For oil and gas producers, the message is clear. Smarter Oilfield Operations isn’t just about keeping up; it’s about staying profitable and sustainable in a changing industry.
As energy markets evolve and new technologies emerge, the companies leading the way are investing in Smarter Oilfield Operations.
Through projects like this one, DSI demonstrates how oil and gas automation modernization can deliver both immediate and long-term benefits. The integration of regenerative drive systems doesn’t just reduce energy costs, it builds resilience. For example, it improves uptime and supports companies’ commitments to carbon reduction and responsible operations.
“Every customer we work with has the same goals,” Johnston says. “They want to be efficient, reliable, and safe. Our job is to make sure the technology supports those goals, not the other way around.”
The Bottom Line: Partnership That Powers Progress
This collaboration between DSI, Rockwell Automation, and the customer stands as a model for what’s possible when innovation meets practical expertise.
By combining Rockwell’s advanced drive technology with DSI’s system integration and field capabilities, the team delivered measurable value:
- Millions in projected energy savings
- Reduced operational costs and maintenance
- Improved reliability and sustainability
Most importantly, the project demonstrates how trusted partnerships drive lasting change in the oil and gas industry.
For producers looking to modernize their operations, the path forward is clear. Smart automation, proven integration, and partners who understand the field.
About the Guest
Casey Johnston is the President of Design Solutions & Integration (DSI), where he leads a team of engineers, automation experts, fabricators, and field service professionals focused on delivering automation, electrical, and integration solutions across the energy and industrial sectors. With almost 20 years of experience, Casey brings deep expertise. In areas such as systems engineering, controls design, and project management for complex industrial applications.
About Design Solutions & Integration
Design Solutions & Integration (DSI) is a 100% employee-owned company providing automation, electrical, fabrication, and field service solutions to the energy and industrial markets. As a Rockwell Automation PartnerNetwork™ system integrator, DSI helps clients modernize aging systems, improve efficiency, and operate more sustainably. With locations across North America’s major energy regions, DSI delivers vertically integrated support from design through implementation and service.
Learn more at relyondsi.com.
