Retrofitting automation equipment used in oil and gas manufacturing can extend the useful life of a machine, replace obsolete controls, improve diagnostics, and adapt an existing process to new operating requirements. A successful retrofit starts with a careful assessment of the equipment and a practical shutdown plan—not simply a list of replacement components.

This checklist helps maintenance, engineering, and operations teams prepare for an oil and gas automation retrofit. For BP Automation’s broader capabilities, visit the oil and gas automation page.

1. Define the reason for the retrofit

Begin by documenting the problem that the project must solve. Common drivers include obsolete PLC or HMI hardware, unavailable replacement parts, unreliable motion controls, weak diagnostics, production changes, or a need to integrate new equipment.

Separate essential outcomes from optional improvements. A clear priority list helps the engineering team decide which existing elements can remain and which must change.

  • What failure or limitation is affecting production?
  • Which components are obsolete or difficult to support?
  • Has the product, material, or process changed?
  • Are operators relying on manual workarounds?
  • What measurable result should the retrofit achieve?

2. Assess the mechanical condition

New controls cannot correct every mechanical problem. Inspect the machine structure, bearings, guides, gearing, actuators, fixtures, guarding, process tooling, and material-handling components. Record excessive wear, backlash, corrosion, deformation, leaks, and alignment issues.

If the mechanical platform cannot support the required load, accuracy, speed, or service life, a new custom machine may be more appropriate. BP Automation’s guide to machine retrofit versus a new custom machine explains the main decision factors.

3. Inventory the electrical and controls system

Create an inventory before selecting replacement hardware. Include the PLC, HMI, drives, motors, remote I/O, safety devices, sensors, encoders, process controllers, network equipment, and control-panel components.

Collect the following where available:

  • Electrical schematics and panel layouts.
  • PLC, HMI, robot, drive, and recipe backups.
  • Software versions and communication protocols.
  • Current alarm and I/O lists.
  • Motor, actuator, and instrument nameplate information.
  • Spare-parts inventory and known obsolescence notices.
  • Records of recurring electrical or control failures.

For controls modernization options, review BP Automation’s PLC automation systems and custom machine controls.

4. Capture the current operating sequence

Older equipment may have undocumented modifications. Observe the machine in production and compare actual operation with the available drawings and programs. Interview operators and maintenance personnel about startup, normal production, changeover, shutdown, manual modes, and fault recovery.

Document temporary jumpers, disabled alarms, manual bypasses, and external devices added after the original installation. These details influence the new control narrative and commissioning plan.

5. Define production and process requirements

A retrofit should be designed around the current and expected process. Provide the part range, material, cycle time, batch size, process parameters, quality requirements, changeover needs, and upstream or downstream interfaces.

For welding, cladding, cutting, or inspection equipment, identify which process variables must be controlled, displayed, recorded, or protected from unauthorized changes. Do not assume that the original sequence remains suitable simply because the machine still operates.

6. Review the operating environment

Oil and gas manufacturing equipment may operate around dust, fumes, vibration, temperature changes, moisture, abrasive material, and electrical noise. These conditions affect enclosures, cooling, connectors, sensing methods, cable routing, and component selection.

Record the installation location, available utilities, environmental conditions, floor space, access route, lifting equipment, and any site-specific requirements. If a hazardous-area classification applies, provide the formal classification and owner requirements to the engineering team.

7. Reassess machine safety

A controls retrofit changes how the equipment starts, stops, detects faults, and responds to people entering the work area. The safety concept must be evaluated for the actual machine and task.

Review guarding, access points, emergency stops, interlocks, safe stopping behaviour, stored energy, lockout points, maintenance access, and recovery procedures. Clarify who is responsible for the hazard assessment, owner approval, validation, and operator training.

8. Plan PLC, HMI, and network migration

Decide whether the project will reproduce the existing sequence, improve it, or replace it with a new functional specification. Define naming conventions, operator roles, alarm priorities, recipes, trends, data retention, and required communication with plant systems.

The migration plan should address:

  • Conversion or rewrite of PLC and HMI software.
  • Replacement of remote I/O, drives, or network hardware.
  • Interface testing with retained equipment.
  • Cybersecurity and remote-support requirements.
  • Backups, version control, and final source-code ownership.
  • Fallback options if commissioning cannot be completed in the planned window.

BP Automation also provides industrial machine retrofit services for existing equipment.

9. Build a realistic shutdown plan

Production downtime is often the most important constraint. Separate work that can be completed before shutdown from work that must occur on the machine. Panels, software, drawings, fixtures, and test procedures may be prepared in advance when sufficient information is available.

Include time for isolation, removal, installation, wiring, I/O checks, dry-cycle testing, process testing, acceptance, training, and production support. Add contingency for undocumented wiring, failed retained components, and access restrictions.

10. Define testing and acceptance

Agree on measurable acceptance criteria before installation. Depending on the project, these may cover sequence operation, cycle time, part range, process output, alarms, safety functions, data collection, changeover, and recovery from common faults.

Identify the parts, consumables, operators, inspection method, and production conditions that will be used. Factory acceptance testing can reduce site risk, while site acceptance testing confirms operation after the retrofit is connected to the actual equipment and utilities.

11. Prepare documentation and support requirements

Specify the required electrical drawings, software backups, component manuals, spare-parts list, operating instructions, maintenance procedures, and training. Decide how future changes will be documented and who will control program access.

Post-commissioning support should reflect the equipment’s importance to production. BP Automation’s maintenance and support services can be considered as part of the overall lifecycle plan.

Information to include in a retrofit inquiry

  • Machine description, age, manufacturer, and current condition.
  • The production problem and desired outcome.
  • Photographs, drawings, manuals, and software backups.
  • Part range, process requirements, and production targets.
  • Controls inventory and obsolete components.
  • Site conditions, interfaces, and owner standards.
  • Available shutdown window and target schedule.
  • Proposed acceptance criteria.

Oil and gas automation retrofits in Alberta

BP Automation is based in Edmonton and supports industrial automation projects across Alberta and Western Canada. Retrofit work may combine PLC and HMI modernization, electrical controls, motion systems, sensors, process equipment, welding automation, material handling, and mechanical modifications.

The first step is determining whether the existing machine is a sound platform for the required process. A structured assessment creates a clearer scope, exposes technical risks, and improves the basis for estimating and scheduling.

Frequently asked questions

Can only the PLC and HMI be replaced?

Sometimes. Feasibility depends on the condition and compatibility of the retained drives, I/O, sensors, safety components, networks, and mechanical equipment. The complete control architecture should be assessed before defining the scope.

Should old PLC code be converted or rewritten?

The answer depends on code quality, documentation, platform compatibility, process changes, and risk. A direct conversion may preserve undocumented behaviour, while a rewrite requires a reliable functional specification and careful testing.

How can commissioning downtime be reduced?

Complete as much engineering, panel construction, software development, simulation, documentation, and interface testing as possible before shutdown. Reliable backups, accurate drawings, representative test parts, and a defined rollback plan are also important.

Can a retrofit add production data collection?

Yes, if the required signals and interfaces are available or added. Define the data, retention period, user access, network connection, and cybersecurity requirements during scoping.

When is a new machine the better option?

A new machine may be preferable when the existing structure or process cannot meet the required safety, capacity, accuracy, maintainability, or service-life goals. Compare lifecycle cost and production risk rather than considering initial capital cost alone.

Planning an oil and gas automation retrofit? Contact BP Automation or call (780) 448-9338 to discuss the equipment and project requirements.