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Oil & Gas

Centralized IoT device lifecycle management for oilfield operations

$38M
avg. annual downtime cost targeted for reduction
Early anomaly detection
via continuous telemetry
tech stack
ReactJS, C#, PostgreSQL, Chart.js, Azure, Docker, Kubernetes, Argo CD, Playwright, SonarQube, Microsoft Entra, MQTT, SSH, mTLS
AT A GLANCE

A Fortune 500 oilfield services company partnered with Zemoso to solve a fundamental challenge: How to run hundreds of IoT devices across distributed oilfields without fragmentation, delays, or risk. Fragmented workflows, inconsistent module deployment, and siloed telemetry were limiting operational control and slowing innovation.Zemoso built a centralized, modular IoT management platform that unified onboarding, module orchestration, and telemetry pipelines into a single intelligent system. Beyond reducing downtime, the platform created a foundation for predictive maintenance, autonomous operations, and operational insights at a planetary scale.

CORE CHALLENGEs

Unplanned downtime costs oil and gas operators an average of $38 million a year, and this client's legacy processes made that risk worse: devices onboarded manually, certificates installed through field-level interventions, and software modules deployed inconsistently across teams with no unified framework tying together SAP-based ordering, Azure IoT Hub connectivity, and a distributed sensor network. Security was non-negotiable throughout, requiring hardware-backed authentication and end-to-end encryption at every stage.

the engineering approach

Zemoso designed a resilient, composable IoT platform capable of managing distributed oilfield devices while maintaining security, reliability, and operational intelligence.

  • Modular microservices architecture: Independently orchestrated services handle device registration, module deployment, telemetry ingestion, and alerting, ensuring the system can evolve without breaking existing operations.
  • Secure, certificate-based communication: End-to-end mTLS with hardware-backed YubiKey authentication and EST-managed certificates guarantees trust between devices, hubs, and backend services.
  • Dynamic telemetry routing: MQTT-based pipelines intelligently prioritize and route telemetry from devices to processing hubs, enabling proactive anomaly detection without human intervention.
  • Cloud-native, GitOps-ready platform: Kubernetes, Docker, and Argo CD enable fully automated deployments and elastic scaling across hundreds of sites, supporting fleet-wide orchestration.
  • Extensible Interfaces for Teams and Clients: ReactJS dashboards and charting modules provide tailored visibility to operations teams while maintaining robust access controls, allowing future extensions like AI-based predictive analytics without re-architecture.
bottom line

Zemoso reimagined device lifecycle management at planetary scale - turning what was once a patchwork of siloed devices into an intelligent, self-orchestrating network. The client can now minimize downtime, deploy modules reliably across hundreds of devices without field intervention, and build on a secure, extensible architecture that future-proofs oilfield IoT for years to come.

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