Stratus Enginuity Global - Case Study

Case Study

Edge Computing in Upstream Oil & Gas Enginuity Global modernized legacy control systems at QuarterNorth Energy’s Bullwinkle production platform for operational excellence and safety in 45 days

Overview QuarterNorth Energy, a leading oil and gas producer operating deepwater assets in the Gulf of Mexico, is known for its innovative and disciplined approach to production management. The company’s Bullwinkle offshore production platform, the largest fixed offshore platform in the U.S., plays a critical role in connecting new wells to existing export flow lines.

However, like many aging assets, Bullwinkle faced challenges with outdated legacy infrastructure and an unsupported control system. With Penguin Solutions edge computing platforms, QuarterNorth Energy modernized its operations, enabling reliable performance, streamlined processes, and no unplanned downtime.

Challenges

Solution

•

Outdated servers, workstations,

• Penguin Solutions

and controllers caused extended

Stratus ftServer

downtime and were costly to repair

platform running 12 virtual

yield, improved safety, and

machines (VMs)

downtime-free operation

• Decentralized control systems required a large number of staff to monitor operations • System complexity hindered troubleshooting

TM

control system resulting in higher

distributed control system

• Consolidated 12 applications

(DCS), including:

running on six servers onto a single,

−

Stratus ftServer compute platform

HMI/SCADA and Factory Talk® historian with SQL

decision making, and visibility −

Control system/safety system at capacity with no headroom

fault-tolerant

for critical applications

of seconds slowed reaction time,

•

• Centralized monitor and

• Rockwell Automation PlantPAx®

• System response time in the tens

on operations

Benefits

−

to increase logic if needed © 2026 Penguin Solutions Edge Computing in Upstream Oil & Gas Case Study - 01.2026

• Contributed to a 22% reduction

Server supporting 6,000

in unplanned downtime,

input/outputs (I/Os)

increasing productivity

Anti-virus and cluster

• Reduced system response time

management software

by 1,000% (from more than 20

System integration by

seconds to just milliseconds)

Enginuity Global, LLC

QuarterNorth Energy modernizes Bullwinkle platform for operational excellence QuarterNorth partnered with Enginuity Global, a leading system integrator specializing in process automation, control, field services, and emergency support, to modernize and centralize Bullwinkle’s infrastructure and control systems—enhancing operations and minimizing downtime.

The Enginuity team migrated the platform from nine legacy programmable logic controllers (PLCs), six servers, and low bandwidth data communications with a fully redundant, platform-wide control system. This modernization, running on a single Stratus ftServer platform from Penguin Solutions, centralized operational applications and enabled seamless data sharing across the platform and to the enterprise.

The team accomplished this significant transformation in 45 days from site acceptance to facility restart. The Stratus platform provides fault-tolerant computing to run the Bullwinkle’s critical applications with no unplanned downtime or data loss, is serviceable by operational technology (OT) teams, and significantly lowered total cost of ownership (TCO).

Upgrading an aging platform to an efficient asset The existing Bullwinkle system presented several challenges to the company’s operating model. Over years of continuous updates, the control system devolved into a decentralized architecture that required more than 20 operators to roam the 384-foot tall platform to monitor screens spread out over several locations. Additionally, parts of the system were near obsolete with aging components that could unexpectedly fail.

Replacing parts was difficult, requiring long lead times to find and replace parts. At times the team resorted to sourcing older components on eBay. As a result, the system was continuously at risk of experiencing a costly and unplanned downtime event.

© 2026 Penguin Solutions Edge Computing in Upstream Oil & Gas Case Study - 01.2026

To modernize and centralize the Bullwinkle system’s control and safety operations, Enginuity Global worked with QuarterNorth Energy to execute a two-phased approach. This project replaced the existing servers and workstations with a single redundant Stratus ftServer platform, consolidated disparate multi-brand software into a single Rockwell Automation PlantPAx automation and control suite, upgraded the existing Allen-Bradley® PLC-5® controllers to Rockwell Automation ControlLogix®, and updated the existing daisy chained remote input/output (I/O) connections to a dual ring-based ethernet network for full system redundancy throughout the platform.

According to Eric Belgard, Enginuity Lead for Automation and Controls, managing the process in phases “lessens the pain” of a major overhaul while also making it easier for companies to keep projects within their budgets.

The primary focus throughout this project was delivering a system that guaranteed personnel safety, enhanced operator awareness, and increased reliability while ensuring supportability, which is essential both for both the customer and the system integrators that support it. A key part of Enginuity’s approach included Penguin Solutions Stratus ftServer, which provides the fault tolerance and scalability to meet QuarterNorth Energy’s current and future needs for running critical applications on a single compute platform.

Not only does the Stratus platform deliver the performance required to run multiple applications on Bullwinkle, but it also provides easier management for the platform’s operators, with customer-replaceable units (CRUs) that are easily installed by OT teams without incurring downtime. And, like QuarterNorth Energy, Penguin Solutions support runs 24/7, enabling the quick resolution of support calls at any time. Once Enginuity evaluated several alternatives, it found the Stratus ftServer platform offered the greatest reliability and the lowest TCO.

© 2026 Penguin Solutions Edge Computing in Upstream Oil & Gas Case Study - 01.2026

Having the Stratus server there gives us peace of mind because the Stratus server is truly fault-tolerant. It’s one of the main reasons why we always choose to go Stratus server when available.

Eric Belgard Lead Systems Engineer Enginuity Global, LLC

Virtualization and reliability with Stratus ftServer platform The first phase in the modernization project focused on updating the automation and control software and replacing the multiple servers and workstations with a single edge computing platform. Prioritizing its focus on oil, well, and transport operations, QuarterNorth Energy wanted a solution that was simple to operate, had no failover time, and prevented data loss. The Stratus ftServer supports 16 thick and thin clients, replacing the six servers and 16 workstations that repeatedly failed and were at or beyond their end-of-life (EOL). As a fault-tolerant compute platform, the Stratus ftServer provides hot-swappable components and automatic health monitoring. Using application virtualization, the team consolidated 12 applications onto the single Stratus system, further simplifying management and reducing costs. In addition, the eight-toten-year lifespan of the Stratus ftServer means that the company no longer has to invest in replacing obsolete hardware every three to four years.

Client/Workstation Overview Stratus ftServer TM

• HMI Server Primary

• Domain Controller

• OPC Server

• HMI Server Secondary

• Asset Center

• Cluster Management

• Factory Talk Historian

• Tag Server

• Engineering Workstation 1

• SQL Server

• Antivirus Server

• Engineering Workstation 2

Office

Control Room

Compressor Deck

Middle Deck

Lower Deck

HIMI Network

Office

Office

Office

Office

Upgraded process control and safety systems enhance compliance, safety, and decision-making The second phase of the modernization project migrated the existing control system to connect to Rockwell Automation PlantPAx running on the Stratus ftServer.

The aging Allen-Bradley PLC-5 units were outdated and had reached the limit of their capacity, with no room for additional logic. Control operations had been combined with the safety monitoring system, creating challenges with compliance.

Response time in the decentralized system was slow: An operator would issue a command and then have to wait 10 to 20 seconds to see the results. In addition, there was no consistency in the multi-brand human-machine interfaces (HMIs), with each requiring different terminals or monitors and having different alarms and trends.

Enginuity replaced the existing PLC-5 units with a new redundant control system based on the PlantPAx DCS, separating the process control systems (PCS) and safety shutdown system (SSDS) into separate processors and racks. It converted legacy PLC-5 controllers connected to the PlantPAx DCS using conversion kits from Rockwell Automation, allowing them to re-use existing wiring for more than 100 I/O panels and 6,000 I/O points. Enginuity then installed a new ethernet network organized

© 2026 Penguin Solutions Edge Computing in Upstream Oil & Gas Case Study - 01.2026

into two redundant fiberoptic rings. In addition to slashing the response time from tens of seconds to milliseconds—a 1000% improvement in speed—the new ethernet network provides a modern, standards-based protocol that is not only faster and more reliable but also easier to support and maintain.

The modernized system dramatically improved the safety of the platform’s operations—a critical success factor for QuarterNorth Energy. Michael Kinzel, QuarterNorth Automation and Controls Engineer, emphasized, “Reliable system response speed is critical for continuous operations.” As part of its safety management process, QuarterNorth performs simulations of different events and measures the time required to respond and react. During a simulation of an abnormal process it noted that response time dropped from tens of seconds to less than three seconds. This remarkable reduction means that operators can react faster during unplanned events.

The new solution also enhances traceability, including the automatic tracking of alarms, bypasses, and other events that are critical to ensuring safety and compliance. Because the previous system lacked this capability, operators had to build audit trails by manually tracking who performed activities and when they occurred. The automatic tracking of all events in the new system—including who did what, when, and for how long—provides a better record of events, enhancing safety and supporting compliance. The resulting DCS is both performant and fully redundant, offering visibility and control while making it easier and safer for operators to work on multiple systems from anywhere on the platform.

Redundant Ethernet I/O network Redundant Process Switches

Remote IO Remote IO Redundant PCS PLC IO Network PRP Ring

Redundant SSDS PLC

Remote IO Remote IO

Remote IO 3rd Party PLC5

© 2026 Penguin Solutions Edge Computing in Upstream Oil & Gas Case Study - 01.2026

DH+

Remote IO

Usability and serviceability built for OT Another important advantage of the newly installed PlantPAx DCS system is the reduction in operator workload. Instead of having to learn and manage multiple interfaces, operators can now view data through standardized HMI screens. Improved data collection speeds up the data historization process, supporting faster and more informed decision making. Leveraging virtualization to consolidate workloads from 12 different applications onto one system eliminates islands of automation and supports application availability. Thick and thin clients managed with Rockwell Automation’s ThinManager® and located throughout the platform provide better access, allowing technicians to manage operations from any location on the platform. The new system also reduces operational complexity, both in terms of the management and monitoring of systems and their regular maintenance.

Due in part to this new architecture, the QuarterNorth Energy deepwater operations team has reduced unplanned downtime on the Bullwinkle production platform by 22%, increasing productivity. Built-in redundancy from the Stratus ftServer and the dual ethernet networks to the PCS and SSDS panels ensure that the system is running and available at all times.

“We have noticed the number of calls reporting server or system downtime has dropped—especially in comparison to the amount of previous cases,” remarked Belgard.

© 2026 Penguin Solutions Edge Computing in Upstream Oil & Gas Case Study - 01.2026

The Stratus ftServer is a tank. It offers a simplistic approach to a complex system.

Part of our motto at Enginuity is, ’We simplify a complex world.’ And so, Stratus servers definitely help reduce some of that complexity. And, we were able to save a substantial amount of money using them.

Eric Belgard Lead Systems Engineer Enginuity Global, LLC

Looking forward: A scalable solution with room for growth QuarterNorth’s Michael Kinzel sees several opportunities to further improve operations on

This architecture really works.

the Bullwinkle platform. The company plans to further streamline its infrastructure by porting

Michael Kinzel

applications running on several less reliable

Automation and Controls Engineer

independent devices to the Stratus ftServer.

QuarterNorth Energy

Highlighting the Stratus system’s virtualization and system availability, Kinzel explained, “We can do this because we have confidence in the Stratus ftServer.” In fact, the solution works so well that QuarterNorth Energy is in the process of setting up a similar engagement with Enginuity to modernize another location.

Contact Us For sales queries, please contact sales@penguinsolutions.com.

To learn more about Stratus ftServer from Penguin Solutions, please visit: www.penguinsolutions.com

© 2026 Penguin Solutions, Inc. All rights reserved. Penguin Solutions and Stratus ftServer are trademarks within the family of companies owned by Penguin Solutions, Inc. All other trademarks are the property of their respective owners, and no claims of ownership are asserted therein.