Three Things Modern Process Automation Should Deliver for an Oil and Gas Operator
Ask five operators what they want from process automation and most will say the same three things: they want to see what’s happening across their sites, they want it to keep working without a tech on standby, and they want it to handle the next well pad without a redesign. That combination, visibility, reliability, and room to grow, is what process automation that scales actually looks like.
Most automation delivers one of the three. Visibility without reliability means a dashboard full of alarms nobody trusts. Reliability without scale means a system that works great until the operation grows past it.
DSI builds toward all three from the first panel, because a system that only does one of them is a system the operator will be replacing within a few years anyway.
Why Legacy Automation Becomes a Liability as Operations Grow
Many automation systems in oil and gas were built to solve one problem at one site. At the time, that approach worked. The challenge appears as operations expand. Systems that were never designed to grow become difficult to modify. Simple updates feel risky. Downtime increases.
Thompson sees this often. Operators rely on systems that “have worked for 20 years” until they suddenly need major changes. At that point, upgrades become expensive and disruptive. Experience loss adds pressure. As senior technicians retire, fewer people understand legacy systems. Automation leaders must support complex operations with less field knowledge and limited visibility.
As Thompson explains, “It becomes a training mission as much as it is assisting the customer.”
Building Process Automation That Scales From Day One
Effective industrial process automation in oil and gas starts with design. Systems must allow room to expand, even when future needs are unclear. Planning for growth reduces the need for rushed add-ons later.
Testing and commissioning are just as important. DSI uses structured cause-and-effect testing so teams know how systems should respond before startup. “It’s not a guessing game in the field,” Thompson says. Clear logic shortens commissioning time and builds confidence.
Integration also plays a key role. When PLC and SCADA integration are handled together, data moves cleanly from devices to operators. Consistent platforms improve troubleshooting and alarm response. Strong process automation systems replace assumptions with reliable logic and repeatable performance.
The Payoff: From 70 Percent Uptime to Over 90
When automation is designed well, results are easy to see. Uptime improves. Response times shrink. Reliable oil and gas automation data helps teams make faster decisions with less risk.
Thompson has seen uptime improve from roughly 70 percent to over 90 percent by focusing on solid programming and commissioning. Integrated teams also move faster. One integrator who understands wiring, instrumentation, and programming reduces handoffs and delays.
Modern automation also supports emerging tools like predictive analytics. Early detection of abnormal trends allows teams to act before failures occur. Visibility across the system helps operators stay proactive instead of reactive.
Conclusion
Industrial process automation in oil and gas should deliver more than control. It should provide visibility, scalability, and confidence across operations. Systems designed with growth in mind help teams avoid costly rebuilds and reduce downtime.
David Thompson’s experience shows that automation works best when integrators understand the full system, not just the code. Reliable data, strong testing, and integrated teams give operators an advantage in an industry where experience is harder to replace.
About the Guest
David Thompson is the Automation Manager for the North District at Design Solutions & Integration. He has nearly 20 years of experience supporting oil and gas automation, PLC programming, and SCADA systems across field operations.
About the Company
Design Solutions & Integration (DSI) is a faith based, 100 percent employee-owned company with more than 25 years of experience in the oil and gas industry. With 125 employees and operations across the Bakken and Permian Basin, DSI delivers electrical, automation, fabrication, engineering, and turnkey field services. The company focuses on integrity, long term partnerships, and high-quality solutions built through a vertically integrated model. Learn more at www.relyondsi.com.
